Fusible link replacement alternative - Dodge Cummins Diesel Forum
89-93 Tech Articles Tech Articles for the 89-93 12V Dodge Cummins Diesel...NO ADVERTISING

 12Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 37 (permalink) Old 01-03-2017, 10:07 PM Thread Starter
Diesel Freak
 
Truckjerk's Avatar
 
Join Date: Nov 2008
Location: Zebulon, NC
Posts: 549
Thanks: 29
Thanked 80 Times in 61 Posts
Garage
iTrader Score: 0 reviews
Fusible link replacement alternative

During the restore on my 93 D250, I installed a remote PDM (PNDB module) from a Freightliner M2 truck along with a 31 series screw top battery, and new cables in order to be done with the fusible link mess that is so problematic on these trucks.

It turned out to be a very nice upgrade to get rid of those fusible links, and be done with their corrosion and problems for good. Ive had a 31 series battery in the truck for years, with post top adapters. It was a complete mess with all the wires attached to the battery, and the rats nest I had with the fusible links.

Here is what I started with the fusibles on the main engine harness. Years ago, a fusible link blew on me in the dead of winter and started a small fire on the fender harness; and we repaired it "till spring" when it could be fixed properly...I found the rubber junction (broom) all corroded up and now slightly charred due to the small fire from the fusible burning. We removed it in -10 degrees, and this rats nest was born...I have to say, it did work fine for about 13 years...LOL:



Here is the solution, Main PNDB, Freightliner part number A06-72138-012; which is available for around $80; an alternative, if you want a simple battery disconnect switch, A06-72138-013--(you can wire up a low voltage rocker switch in the cab and disconnect the battery remotely, pretty convenient, about $150 for that one).



It includes 3 MIDI fuse connections, and 4 standard ATC blade fuse holders. I do not recommend using the MIDI's that come with it, they are way too heavy for what these trucks run.

Before wiring it up I went thru the entire harness, repaired any damaged wires, and replaced all the dry rotted tape with new vinyl and friction tape, as needed. I also went thru each circuit with a fusible link and identified what it feeds to be able to correctly size the fuses. Here is what the wires feed; in summary, with the fuse sizes I used after identifying the circuits. This is for 1991.6-93 trucks, 90-91.5 are slightly different. Check a wiring schematic for exact components.

40A MIDI; 12ga Pink/Black = Ignition Main Feed
40A MIDI; 12ga Red = Ignition Main Feed
40A MIDI; 12ga Red/White = Exterior Lamps/Headlamp Switch
30A ATC; 12ga Black/Red = Accessories/Power Mirrors
15A ATC; 16ga Pink = Hazard Flasher
100A Remote MIDI; 6ga Black = Alternator Main
30A ATC; 14ga Brown = ASD/Fuel Shutoff Solenoid Relay
40A MIDI; 12ga Red = Starter Relay (paired with 12ga Red/White, no fusible from factory)
20A ATC; 16ga Orange = ECM/A/C Relay

After finding all the wires and separating them, I made a new harness connection in the main engine harness. All connections soldered and covered with heat shrink tubing. Leave plenty of extra wire for locating the PDM:




I also added an extension onto the 6ga alternator feed to allow me to connect a remote MIDI fuse to it.

Here is everything cleaned, taped, and loomed together, and the new location for the PNDB mocked up. I used metal crimp ring terminals at the PNDB connections, soldered with heat shrink. The 4 pin connector in the PNDB is Freightliner part numbers 23-13153-410, FCI/10762803, FCI/10757690 (X2), and FCI/10762802, (this left me with an extra in case I damaged a terminal)...make sure to get yourself a good set of terminal connector crimpers for this, regular butt connector crimping tools will not work. The connector is very easy to put together once you crimp the terminals in, just snap them into the housing. I also put a bit of solder on the terminals for an extra secure connection.


Now to mount the PNDB, I used these rubber studded isolators from a Freightliner, part number 03-35804-000.


Pick a good dry location, and mount the PNDB with the two isolators. I picked the fender well rather than the inside of the fender, in case rain/water got in between the hood and fender. Once the splash shield is installed it will be high and dry. I also recommend spraying the terminals with a battery terminal protective coating. Freightliner makes a paint for this, and I will be coating mine with it here soon.


Here is the 2/0 main feed cable to the battery. I made this using a standard 2/0 x 5/16 terminal end, and a 90 degree battery terminal connector (Freightliner number 23-12776-123). I also connected the grid heater relays and alternator fuse to this terminal. I used a positive and negative cable from a Freightliner, part number JEI/28SP9873R110 (red) and JEI/28SP9851B062 (black), and cut them to the length needed, and crimed on new terminals for the starter, and engine ground. I also made a 2/0 engine to frame ground, and a 6ga battery to body ground off of the extra wire from the alternator circuit.




The new fuses in the PNDB:


Here is everything installed;



Hopefully this gives you a few ideas and helps you get rid of your fusible link problems. If you have any questions about my install feel free to ask.


2014 Ram 2500, 6.7, 6 Speed Manual
1993 Ram D250, 2WD Cummins 5-speed.
Truckjerk is offline  
The Following 12 Users Say Thank You to Truckjerk For This Useful Post:
1992 Renegade (01-14-2017), 9297oldram (01-04-2017), cabbage658 (01-12-2019), clutchcan (04-02-2017), Diesel_Dawg (01-04-2017), disgoup (01-09-2017), grizzlypaugh (03-05-2019), justinfonder (01-04-2017), jwh06 (03-31-2017), mopeman (01-03-2017), thrashingcows (01-04-2017), TruckTor (03-30-2017)
Sponsored Links
Advertisement
 
post #2 of 37 (permalink) Old 01-03-2017, 10:51 PM
Cummins Nut
 
Join Date: Oct 2012
Location: Here
Posts: 391
Thanks: 24
Thanked 35 Times in 35 Posts
iTrader Score: 1 reviews
Very nice!!! I have been dreading the day I have fusible link issues and now this is a great way to fix it for good. What are the specs on the battery you installed?

07 3500 SLT QCLB 4x4 5.9er G56 traded for...12 3500 Laramie CCLB 6.7 4X4 68RFE traded for...04.5 2500 ST RCLB 4x4 5.9er 48RE...
To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.
sold for 93 W250 LE 4x4 5.9er G360...
To view links or images in signatures your post count must be 3 or greater. You currently have 0 posts.
mopeman is offline  
post #3 of 37 (permalink) Old 01-03-2017, 10:56 PM Thread Starter
Diesel Freak
 
Truckjerk's Avatar
 
Join Date: Nov 2008
Location: Zebulon, NC
Posts: 549
Thanks: 29
Thanked 80 Times in 61 Posts
Garage
iTrader Score: 0 reviews
Quote:
Originally Posted by mopeman View Post
Very nice!!! I have been dreading the day I have fusible link issues and now this is a great way to fix it for good. What are the specs on the battery you installed?
Thanks, battery is a 31 series, 925 amps at 0*, 1110 amps at 32*; can be had at any Freightliner dealer, part number ABP/31S925; was $60 on sale.
thrashingcows likes this.

2014 Ram 2500, 6.7, 6 Speed Manual
1993 Ram D250, 2WD Cummins 5-speed.
Truckjerk is offline  
Sponsored Links
Advertisement
 
post #4 of 37 (permalink) Old 01-04-2017, 05:23 AM
Cummins Nut
 
Join Date: Feb 2011
Posts: 486
Thanks: 21
Thanked 108 Times in 91 Posts
iTrader Score: 0 reviews
Wow,
That looks very nice.
Jim L is offline  
post #5 of 37 (permalink) Old 01-04-2017, 05:24 AM
Diesel Head
 
justinfonder's Avatar
 
Join Date: Mar 2014
Location: SD/TX
Posts: 4,448
Thanks: 430
Thanked 987 Times in 788 Posts
iTrader Score: 3 reviews
this needs to be made a sticky.
thrashingcows and mknittle like this.

'67 D100 on '89 D350 chassis/12v/a518 --- '88 Ramcharger on '93 W250 chassis/12v/47rh --- '93 W250 race truktor --- '03 1500 shorty 12v/a518 --- ‘12 3500 cclb studded, deleted, tunez, 5”
justinfonder is offline  
post #6 of 37 (permalink) Old 01-04-2017, 10:14 AM
Cummins Fanatic
 
89ralph's Avatar
 
Join Date: Nov 2016
Posts: 155
Thanks: 1
Thanked 6 Times in 6 Posts
iTrader Score: 0 reviews
Quote:
Originally Posted by justinfonder View Post
this needs to be made a sticky.
i agree 100%

89 w250,2nd owner, 160k miles, 727, straight pipe, tuned afc, kdp.
89ralph is offline  
post #7 of 37 (permalink) Old 01-04-2017, 11:58 AM
Diesel Head
 
myother4x4isaCJ7's Avatar
 
Join Date: Aug 2016
Location: Dufur oregon
Posts: 3,528
Thanks: 42
Thanked 323 Times in 303 Posts
iTrader Score: 2 reviews
Quote:
Originally Posted by justinfonder View Post
this needs to be made a sticky.
Yes for sure, clear and easy to follow and he lists all part numbers.

1993 w250 club cab ,flatbed, he351cw, 60# springs, THD Pin, 3200 gov spring,4" diamond eye, THD 5x12 vco and HVLP.
myother4x4isaCJ7 is offline  
post #8 of 37 (permalink) Old 01-14-2017, 02:52 PM
Diesel Head
 
justinfonder's Avatar
 
Join Date: Mar 2014
Location: SD/TX
Posts: 4,448
Thanks: 430
Thanked 987 Times in 788 Posts
iTrader Score: 3 reviews
couple of questions, first, did you get the block straight from Freightliner? haven't found a decent source online for one.

also, you list 4 midi fuses in addition to the remote midi fuse for the alternator but the block only has 3. where does the 4th go?

40A MIDI; 12ga Pink/Black = Ignition Main Feed
40A MIDI; 12ga Red = Ignition Main Feed
40A MIDI; 12ga Red/White = Exterior Lamps/Headlamp Switch
30A ATC; 12ga Black/Red = Accessories/Power Mirrors
15A ATC; 16ga Pink = Hazard Flasher
100A Remote MIDI; 6ga Black = Alternator Main
30A ATC; 14ga Brown = ASD/Fuel Shutoff Solenoid Relay
40A MIDI; 12ga Red = Starter Relay (paired with 12ga Red/White, no fusible from factory)
20A ATC; 16ga Orange = ECM/A/C Relay

'67 D100 on '89 D350 chassis/12v/a518 --- '88 Ramcharger on '93 W250 chassis/12v/47rh --- '93 W250 race truktor --- '03 1500 shorty 12v/a518 --- ‘12 3500 cclb studded, deleted, tunez, 5”
justinfonder is offline  
post #9 of 37 (permalink) Old 01-14-2017, 03:06 PM Thread Starter
Diesel Freak
 
Truckjerk's Avatar
 
Join Date: Nov 2008
Location: Zebulon, NC
Posts: 549
Thanks: 29
Thanked 80 Times in 61 Posts
Garage
iTrader Score: 0 reviews
Quote:
Originally Posted by justinfonder View Post
couple of questions, first, did you get the block straight from Freightliner? haven't found a decent source online for one.

also, you list 4 midi fuses in addition to the remote midi fuse for the alternator but the block only has 3. where does the 4th go?

40A MIDI; 12ga Pink/Black = Ignition Main Feed
40A MIDI; 12ga Red = Ignition Main Feed
40A MIDI; 12ga Red/White = Exterior Lamps/Headlamp Switch
30A ATC; 12ga Black/Red = Accessories/Power Mirrors
15A ATC; 16ga Pink = Hazard Flasher
100A Remote MIDI; 6ga Black = Alternator Main
30A ATC; 14ga Brown = ASD/Fuel Shutoff Solenoid Relay
40A MIDI; 12ga Red = Starter Relay (paired with 12ga Red/White, no fusible from factory)
20A ATC; 16ga Orange = ECM/A/C Relay
Yes, all came straight from a Freightliner dealer. It is proprietary stuff, so I highly doubt its available online.

The 4th midi in my list is paired on the same post with the headlamps/exterior lamps circuit (red/white). It is for the starter relay, and had no fusible link from the factory.

2014 Ram 2500, 6.7, 6 Speed Manual
1993 Ram D250, 2WD Cummins 5-speed.
Truckjerk is offline  
post #10 of 37 (permalink) Old 01-14-2017, 03:08 PM
Diesel Head
 
justinfonder's Avatar
 
Join Date: Mar 2014
Location: SD/TX
Posts: 4,448
Thanks: 430
Thanked 987 Times in 788 Posts
iTrader Score: 3 reviews
never mind, i see it now, you have it paired with 12ga red/white. guess i should read better...

'67 D100 on '89 D350 chassis/12v/a518 --- '88 Ramcharger on '93 W250 chassis/12v/47rh --- '93 W250 race truktor --- '03 1500 shorty 12v/a518 --- ‘12 3500 cclb studded, deleted, tunez, 5”
justinfonder is offline  
post #11 of 37 (permalink) Old 01-14-2017, 06:05 PM
Cummins Fan
 
1992d250boss's Avatar
 
Join Date: Apr 2016
Location: Jax Florida
Posts: 86
Thanks: 20
Thanked 4 Times in 4 Posts
Garage
iTrader Score: 0 reviews
very clean install. Awesome!

1992 D250 LE,3in Pusher intercooler pipes,DT stage 2 fuel pin 3600 spring,DDP3 injectors,SS BD pulse manifold,cc billet intake,055T CAT Turbo. 60# springs. Mighty Diesel HB's.Fuse link delete Blue Sea fuse box.Mishimoto Rad.LED instrument cluster upgrade.ISSPRO gauges
1992d250boss is offline  
post #12 of 37 (permalink) Old 01-23-2017, 12:56 PM
Newbie
 
comitche's Avatar
 
Join Date: Oct 2016
Location: TN
Posts: 43
Thanks: 3
Thanked 6 Times in 6 Posts
iTrader Score: 0 reviews
This write-up adds a lot of value to this forum. Thank you for taking the time to do this as it has helped me out and I'm sure will benefit many others in the future. Forum god, will you please make this a sticky?

1992 W250 Auto- SOLD
comitche is offline  
The Following User Says Thank You to comitche For This Useful Post:
Truckjerk (01-23-2017)
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Dodge Cummins Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome