FSS blue fusible link ? - Dodge Cummins Diesel Forum

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post #1 of 6 (permalink) Old 08-12-2009, 03:45 PM Thread Starter
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FSS blue fusible link ?

A brief rundown of what I have already done. Finally traced starting problems to the Fuel Shutdown Solenoid intermittently not opening. I can lift it with my hand and it stays open - no surprise.

Unhooked the wiring harness and tested solenoid by jumping it to 12 volts and it works fine on both run and start side. took it off and cleaned it up (probably going to use disk brake caliper grease to lube it unless someone advises me otherwise) Also going to replace the boot as it is deteriorated.

Tested the relay on the firewall and it is also good. Cleaned the contacts on the blue fusible link and the coating just pulled off, wire still intact. The problem is that it does not say anywhere what gauge or size the blue fusible link is. I've read everywhere that it is a 65 amp link, but don't feel like paying $24 for one from genosgarage.com or fostertruck.com when I know I can get one for about $4 at napa. The guy there said that he thought the blue 18 gauge one was a little thin for that many amps.

Soooo, are they color coded and he is wrong or does anyone know what gauge fusible link that I need.

Thanks in advance for any help.


97 2500 excab 6spd 4x4:intake,4" exhaust,60lb vlv, 4kgsk, afc kit,gauges,#10 plate,16* timing,62/65/13 ss turbo,kdp tab,tranny filter-- SDX II injectors,Valair 13" DD organic.
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post #2 of 6 (permalink) Old 08-12-2009, 04:32 PM Thread Starter
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Also wondering if I should solder on the new one or not as i have heard that soldering raises the resistance. Any truth to this? Should I just crimp on a connector and heat shrink over and call it good?
thanks

97 2500 excab 6spd 4x4:intake,4" exhaust,60lb vlv, 4kgsk, afc kit,gauges,#10 plate,16* timing,62/65/13 ss turbo,kdp tab,tranny filter-- SDX II injectors,Valair 13" DD organic.
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post #3 of 6 (permalink) Old 08-12-2009, 11:19 PM
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All a fusible link is is a smaller gauge wire than the load carrying wire that has flame resistant insulation with a sand like substance inside that acts like a fire extinguisher when it get hot. It's amp rating depends on length and gauge of the wire.

Chrysler has it's own fusible link color code, all links are 6" long
Chrysler colors are:
Black- 12 gauge for 8 gauge wiring
Red- 14 gauge for 10 gauge
Dark Blue- 16 gauge for 12 gauge
Gray- 18- gauge for 14 gauge
Orange- 20 gauge for 16 gauge
White- 22 gauge for 18 gauge

Many mechanics now just replace fusible links with a maxi fuse and holder available at any auto parts store.

Soldering high amp connections isn't recommended, the heat can melt the solder.
Use crimp connectors.

Bill
'95 2500 4wd auto
'95 3500 5 speed heavy hauler
Stock for one day

Last edited by illflem; 08-12-2009 at 11:23 PM.
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post #4 of 6 (permalink) Old 08-13-2009, 07:49 PM Thread Starter
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thanks for the reply. I had already used 14 gauge fusible link. Just went by the old rule of 4 gauges smaller than the primary wire used, which is what you recommended.

97 2500 excab 6spd 4x4:intake,4" exhaust,60lb vlv, 4kgsk, afc kit,gauges,#10 plate,16* timing,62/65/13 ss turbo,kdp tab,tranny filter-- SDX II injectors,Valair 13" DD organic.
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post #5 of 6 (permalink) Old 05-04-2010, 01:56 AM
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where did you buy the link from and did that fix your problem? I'm having the same issue and I was thinking of just getting rid of this link and put in a fuse holder and a standard 60 amp fuse.
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post #6 of 6 (permalink) Old 05-10-2010, 04:17 PM Thread Starter
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sorry this reply is so late. I bought the fusible link from napa for around 8 dollars and it did fix my problem.

97 2500 excab 6spd 4x4:intake,4" exhaust,60lb vlv, 4kgsk, afc kit,gauges,#10 plate,16* timing,62/65/13 ss turbo,kdp tab,tranny filter-- SDX II injectors,Valair 13" DD organic.
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