Fuse Link and Butt Connector Identification
Section 18-01: Wiring and Circuit Protection | 1996 F-150, F-250, F-350, F-Super Duty Chassis Cab, Motorhome Chassis, and Bronco Workshop Manual
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If it becomes necessary to replace a fuse link in a wiring assembly, make sure the replacement fuse link is a duplicate of the one removed with respect to gauge, length and insulation. Original Ford replacement fuse links have insulation that is flameproof. Do not fabricate a fuse link from ordinary wire because the insulation may not be flameproof.
If a circuit protected by a fusible link becomes inoperative, inspect for a blown fuse link. If the fuse link wire insulation is burned or opened, disconnect the feed wire part of the wiring and cut out the damaged portion as close as possible behind the splice in the harness. If the damaged fuse link is between two splices (weld points in the harness), cut out the damaged portion as close as possible to the weld points.
Fuse Link and Butt Connector Identification
| Description | Tool Number |
|---|---|
| Wire Fitting Crimping Tool | T67S-17018-A |
NOTE: Do not mistake a resistor wire for a fuse link. The resistor wire is generally longer and has print stating, "Resistor — don't cut or splice."
NOTE: When attaching a single No. 16, 18 or 20 gauge fuse link to a heavy gauge wire, always double the stripped wire end of the fuse link before inserting and crimping it into the butt connector for positive wire retention.
NOTE: Always attempt to make replacement link as close in length as original damaged link.
To service any blown fuse link use the following procedure:
Determine which circuit is damaged, its location and the cause of the open fuse link. If the damaged fuse link is one of three fed by a common No. 10 or 12 gauge feed wire, determine the specific affected circuit.
Disconnect the battery ground cable.
Cut the damaged fuse link from the wiring harness and discard it. If the fuse link is one of three circuits fed by a single feed wire, cut it out of the harness at each splice end and discard it.
Identify and procure the proper fuse link and butt connectors for attaching the fuse link to the harness.
Strip wires 7.6mm (0.3 inch) and insert into proper gauge wire connector.
Crimp the wires with Wire Fitting Crimping Tool T67S-17018-A and heat splice insulation until tubing shrinks and adhesive flows from each end of connector.
To service a two-link group when only one link has blown and other link is not damaged:
To replace any fuse link on a single circuit in a harness, cut out the damaged portion, strip approximately 12.7mm (1/2 inch) of insulation from the two wire ends and attach the appropriate replacement fuse link to the stripped wire ends with two proper size butt connectors.
If the damaged fuse link is between two splices (weld points in the harness), cut out the damaged portion as close to the weld points as possible.
To repair any fuse link that has an eyelet terminal on one end such as the charging circuit, cut off the open fuse link behind the weld, strip approximately 12.7mm (1/2 inch) of insulation from the cut end and attach the appropriate new eyelet fuse link to the cut stripped wire with an appropriate size butt connector.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect negative battery cable to battery and test the system for proper operation.
