540 vette

I have to replace the fusible links at my starter and at the horn relay. What size do I need for those areas. I did a search and didn't come up with what I needed. And how do I replace them.

Sunstroked

They are listed in the wiring diagram in the factory service manual for the chevelle,camaro, nova, corvette. The book actually has some very useful information. I bought small rolls of fusible link wire in the proper guage and spliced them into the original harness.

540 vette

Thats great that it is in the factory service manual. But the problem is I don't have one and I am looking to get the wire today to finish up the engine compartment wiring. That is why I started this thread so maybe someone with the manual could help me out and let me know.

So does anyone know or has that manual to let me know what size fusible links are needed and where they go. Thank you.

Alan 71

Hi 540,
The fusible links are 4 gauge sizes smaller than the cable they are designed to protect.
At the starter solenoid it's 14 gauge.
At the horn relay it's 16 gauge.
Doing what you're doing without a service manual?!
Regards,
Alan

540 vette

Thanks Alan...again. I unfortunately haven't gotten around to getting one. I only have the car a few months. And with all the "life stuff" I have been dealing with lately it hasn't been on the top of the list.

So the starter one would be 18 gauge and the horn relay 20 gauge.

Alan 71

Hi 540,
No, I gave the fusible-link wire size.
Not buying your excuses one bit.
Regards,
Alan

540 vette

Thanks Alan. Family stuff happens.

jhudec

Here is the page out of the 1972 chassis manual. Although I also find this confusing when replacing the factory fusible link with fusible link wire.


As Alan indicates these are the fusible link wire sizes.
You really need to use the chart and match it to the wiring diagram. I also see 2 fusible links at the horn relay 1 of them is 16ga. and the other is 20ga.
Hope this helps.
Joe

540 vette

Thank you guys. Alan ordered the manual on Amazon today.

7T1vette

Real 'fusible link' wire must have non-flammable insulation...so if (when) the link melts, the insulation will not catch fire. Also, where they join with the regular wiring, you want to put a ball (1/2" diameter maybe) of JB Weld stick epoxy over each joint. This will prevent any chance of the short-duration heat from getting to the insulation of the regular wiring.

By design, the fusible links should never be needed...except for very unusual circumstances that create a dead-short somewhere. But, as yours HAVE been fried, you should realize that it CAN happen again. Rebuild them correctly so no fire can occur.

mrvette

One thing everyone fails to mention, IF you are adding electric cooling fans, upgrading the blower motor/fan combo, or adding anything fancy in sound gear, you need run ALL those off the alternator directly and NOT off the battery + cable....speaking of the main power drag, not the control wiring....

Paul L

Yes for starter (see link to NAPA part). Not sure about horn relay.



You can get bulk fusible links at your local GM dealer. I have many. You have to speak with a parts person who has grey hair. He will know where they are in the back where no one fears to tread or understand.

Sunstroked

So, Im sorry I wasnt more specific. It upset you and for that I apologize. I think I paid $12 for a used 72 manual on ebay.
you see as a lifelong mechanic, only a few more yrs to work, yay! I have learned the value of service/maintenance manuals. In fact I diagnosed and fixed the furnace today with its maintenance/installation manual. It cost me nothing. Except time. I also repair and service the boeing 737 in my day job. I must use manuals, the FAA would be upset if I didnt. The corvette is just a hobby, but even I all knowing brilliant mechanic must lower myself to look in the "book". But hey, what do I know?

540 vette

Well considering I was a line mechanic in multiple dealers for 15 years and and also owned my own shop then went to college at the age of 30 to get an engineering degree I also know the worth of good service manuals. I work with high pressure boilers right now and like yourself have a few more years to go. But considering I only have the car a short time and haven't gotten around to getting one I came to the next best place for an answer, this forum. I am sorry if I came off upset, I wasn't because I knew someone else would be along to give me what I wanted. I have now ordered the manual that I need from Amazon. Thank you for your time.


And thanks to everyone else. That is what this forum is for.

540 vette

Thats where I usually put them, thank you Mrvette.

540 vette

Actually the one I need to change is at the starter and it didn't fry. It just is messed up like the rest of that part of the harness. Thanks.