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I have a 2002 F-250 5.4L 2V CCLB 4WD with 226,000 miles:
The blue arrow captures a "fuseable link connection. Its seems flimsy, how do I correct it? The red power cable feeds into that square plastic black box and then emerges as a step-down wiring, Is this common?. It travels then to the firewall and then to the fuse box. I haven't popped the box that houses the power wire but do all 5.4L have this step down? Why wouldn't the red power cable continue to the firewall? I am stumped. I thought about putting a new red power wire so I need some clarity on this. The connection or the continuation of the trucks power source seems sketchy in the pix. I have been experiencing start/no start on my 2nd Starter (new from O'Reilly) in the last 5 months. I am trouble shooting the issue.
What is the purpose of the Fuse-able links? Are they just crimped and heat shrunk connections?
Last edited by PJWhelan; Nov 13, 2022 at 01:01 AM.
Reason: clarity
First thing to do is to take that red positive battery clamp apart and clean all of the paint off the contact mating area where the cables crimp in. The paint acts as a partial insulator and causes intermittent starter problems. Or, just replace it with an unpainted version.
As for the "flimsy" connection, that's a pair of 12 ga wires inline with a 6 ga cable plus an 18 ga link that feeds a 14 ga wire. It's going to appear "flimsy" in comparison due to the differences in wire gauge. Goes to alternator. Unless the connections or the links have failed, there's nothing to correct.
The connection off the junction block consists of more fuse links. Again, a pair of 12 ga links that splice into a 4 ga cable that feeds to the CJB.
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