Fusible link

Tiny
MMUNZIE
  • MEMBER
  • 1990 FORD F-250
  • 7.5L
  • V8
  • 4WD
  • MANUAL
  • 99,000 MILES
Our truck has gone through many starter solenoids. We need help with the fusible link location, gauge and color.
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Monday, February 13th, 2017 AT 5:29 PM

9 Replies

Tiny
CARADIODOC
  • EXPERT
What is the symptom? Ford used three or four different starter circuits. Are you referring to the relay on the inner fender by the battery, or do you have one mounted on the starter motor?
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Monday, February 13th, 2017 AT 5:32 PM
Tiny
MMUNZIE
  • MEMBER
Yes referring to the relay on the inner fender by the battery.

Thanks!
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Monday, February 13th, 2017 AT 5:34 PM
Tiny
CARADIODOC
  • EXPERT
What is happening to it?
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Monday, February 13th, 2017 AT 5:36 PM
Tiny
MMUNZIE
  • MEMBER
We believe the fusible causes the starter solenoid to short out. We need a diagram for the fusible link so we can chase them down to find the cause. Any suggestions?
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Monday, February 13th, 2017 AT 5:41 PM
Tiny
MMUNZIE
  • MEMBER
I meant the fusible link causes the starter solenoid to short out every time.
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Monday, February 13th, 2017 AT 5:56 PM
Tiny
CARADIODOC
  • EXPERT
That is absolutely not possible. A fuse link is just a piece of wire, but it's slightly smaller than the rest of the circuit it protects, so it's the weak link in the chain, so to speak. If the solenoid is shorted, that will burn out the fuse link wire. More commonly, you have the wrong solenoid. There are three versions that vary by year and transmission type.

You still didn't tell me what the symptom is. Also, what is the history that led up to this? Can you figure out where the fuse link is connected on each end so I can find it on a wiring diagram?
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Monday, February 13th, 2017 AT 6:13 PM
Tiny
MMUNZIE
  • MEMBER
The symptom is the truck will not start once again and that solenoid probably doesn't have more than 400 miles on it.
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Monday, February 13th, 2017 AT 6:34 PM
Tiny
CARADIODOC
  • EXPERT
Does it make a single, rather loud clunk each time you turn the ignition switch to "crank"?
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Monday, February 13th, 2017 AT 6:44 PM
Tiny
CARADIODOC
  • EXPERT
Do you have a test light and know how to use it? If you do, and if the solenoid does make that single loud clunk, use the light to test for 12 volts on the two large studs on the solenoid. One will have 12 volts all the time. The other one should have 12 volts when the solenoid turns on. If you DO find 12 volts on the second stud, a real common suspect is the strands of wire are corroded away under the insulation, right next to the terminal that is bolted to the starter motor. To verify that, test for 12 volts down at the starter. If it's missing there, or low, suspect that cable.

I'll be back tomorrow to see how you're doing.
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Monday, February 13th, 2017 AT 7:30 PM

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