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All About Fusible Links

What is a Fusible Link?

A Fusible link is a short, low-voltage wire that acts as a fuse in a vehicle's wiring harness. Fusible links provide circuit protection in the wiring of a vehicle in the case of a short circuit or voltage spike. Fusible link wires may be used in applications in which an automotive fuse is unsuitable for the voltage demand.

Fusible Link Construction

Fusible links are short pieces of wire. Our Fusible Links feature stranded bare copper conductors and Hypalon rubber insulation. We carry fusible links in gauge sizes 22 AWG to 8 AWG. We also offer multiple colors for the insulation, including Orange/Rust, Grey, Blue, Black, or Red.

Fusible Link Specifications

Since fusible links are classified as low voltage wiring, they should not be used in applications that exceed 50V. Allied Wire and Cable's fusible links have a maximum temperature of 150°C for continuous use. Our fusible likes also meet the SAE J-1128 Type HTS specification.

Common Applications of Fusible Links

Fusible links find widespread use in automotive electrical systems, serving as inline circuit fuses within a vehicle's wiring harness. They safeguard larger wires from voltage spikes, acting as supplementary circuit breakers that bypass the vehicle's fuse box. This protection mechanism not only prevents damage from short circuits or voltage surges but also mitigates the risk of fire in instances of extreme current overload. In the event of a fusible link blowing, the conductor within the link melts, containing any sparks or flames within the insulation. Fusible link replacement becomes necessary to restore circuit integrity and safety.

What Does a Fusible Link Do?

Fusible link wires are suitable for use as an inline circuit fuse in a vehicle's wiring harness. They protect larger wires from voltage spikes by adding a new circuit breaker that bypasses a vehicle's fuse box. They also prevent fire in the case of extreme current overload. If this were to happen, the conductor in the link would melt, and the insulation would contain any sparks or flame that may occur. However, a replacement fusible link will be needed after it has blown.

What Does a Blown Fusible Link Look Like?

When a fusible link wire blows, visual cues indicate its failure. Typically, the insulation surrounding the link may exhibit signs of melting or charring, indicating the conductor's melting within. Additionally, a blown fusible link may appear physically broken or disconnected, disrupting the flow of electrical current. Identifying these visual indicators helps diagnose and address electrical issues within the vehicle's wiring system promptly to ensure removal for a fusible link replacement to be installed.

Bad Fusible Link Symptoms

  • Sporadic or complete loss of power to electrical components
  • Intermittent operation of lights, accessories, or ignition systems
  • Repeated electrical circuit overloads or short circuits
  • Visible signs of melting, charring, or physical damage to the fusible link insulation
  • Inability to start the vehicle due to electrical issues

Allied Wire & Cable Carries Your Next Fusible Link Replacement

Allied Wire and Cable offer 8 to 22-gauge fusible links as part of our extensive stock of automotive wire. Our stock includes brake cables, car speaker wires, trailer cables, battery cables, and primary wires. Our Battery Cable options include SGT, SGX, and STX wire. We carry both PVC and cross-linked primary wires, including GPT and TXL Wire. Do you have more questions about Fusible Links? Read our Automotive Cable FAQs or contact us today!