Here are the most frequently asked questions about fusible link wire. If you require additional information, please, contact us online.
A fusible link is a short piece of insulated low-voltage cable within an automotive wiring harness that is designed to protect the harness in applications where a fuse is unsuitable. In an extreme current overload situation, the conductor within the link is melted while the ensuing flame and spark is contained within the link's insulation.
Fusible links are not rated in amps like fuses because each installation is unique and designed to meet specific circuit protection requirements.
The automotive service industry recommends using the same gauge and length as the blown fusible link after the cause of failure is corrected.
Insert the stripped end of a fusible link and the stripped end of the cable being protected into a parallel connector as shown, and crimp. A parallel connector should always be protected with electrical tape or heat-shrink tubing.
Connecting two wires with a parallel connector
The suitability of a fusible link in a new application can be determined only by a qualified harness engineer with full knowledge of the circuit protection requirements, the installation and operating conditions, and the safety and liability aspects. We cannot make specific recommendations.
Typically, a given harness segment is protected by fusible link that is four gauge numbers smaller. A 14-gauge wire would be protected by an 18-gauge fusible link. A 6-gauge wire would be protected by a 10-gauge link, and so on. Odd number wire gauge sizes like 19, 15, 13 and 11 are counted when sizing a link. The length of a fusible link should not exceed 9".
In general, a fusible link should never be used to replace an automotive fuse unless authorized by a vehicle factory service bulletin. Safety and liability issues are involved
While "MAXI" fuses have replaced most factory-installed fusible links in late model vehicles, they do not have the same performance characteristics as fusible links and should not be used to replace them unless specifically authorized by a vehicle factory service bulletin. Fusible links continue to be used in most starting circuit applications.
SXL wire would work as an emergency replacement, but it would not have the required "Fusible Link" markings and the insulation would not be designed to contain flame and spark in the event of a circuit failure.
Specifications relating to conductors, insulation, wire size, length, location termination, identification and testing are spelled out in SAE Specification J156, The Society of Automotive Engineers' web address is www.sae.org.