Electrical connector diagnosis

[Final777]

Okay I'm back again with yet another problem again that I have run info on my 1986 ranger. On the driver side under the hood you have some big kind of block like electrical connectors. Well a fusible link caught fire on me and the pin thats runs into this connecter is what I need to fix. But exactly how do I go about doing that? I have tried buying things called furrels, I've managed to repair the original one and put the wire back in it but it's come back out again and I don't think I'll be able to repair it I've also used an electrical connector for Ford for the part but every one that I've used doesn't want to go all the way into the slot and stay in place I also cannot find anywhere to buy fusible links anymore they do sell people link wire do I need to replace that with the fusible link wire or can I just run like a fuse to it in between or should I just run the wire by itself please help me I just don't know the best way to replace and fix it. Can anyone please help me out give me any tips at all

 

[RobbieD]

It sure would help us, if you could post some pics of the damaged connector, and what you've done as the repair.

Yes, you can convert from fusible link to a fuse. You'll want to go with a Maxifuse, and a good holder for it.

 

[Final777]

Well I don't know how much I may be able to explain it but I am going to do my best The part that I circled in the diagram is my 20 gauge fusible length wire that burned up on me the whole thing burnt up all the way up to the connector so I had to wind up replacing the wire, the fusible link and the pin that is connected to the wire. I tried to use the connector that was originally in it and it worked pretty well until the wire came out again. One thing I was wondering and wanted to ask if there any place I can get these actual pens that go into connector that are the exact same kind that Ford made them or is there are some other kind of substitution for all and what should I use a maxi fuse or can I use fusible link wire that u can buy from advance and autozone?

 

[Angie]

if you can't find the same style plug, i would just wire the thing using this style of plug and female connectors. if your wiring skills are good. and use shrink tubes to make a tight connection around the crimps. hope this may help. as you can also add more to the line if you need fuses or stuff. cheers.

Hilitchi 100pcs 22-16 Gauge Insulated Male/Female Bullet Quick Splice Wire Terminals Wire Crimp Connectors Set : Amazon.ca: Tools & Home Improvement

Hilitchi 100pcs 22-16 Gauge Insulated Male/Female Bullet Quick Splice Wire Terminals Wire Crimp Connectors Set : Amazon.ca: Tools & Home Improvement

www.amazon.ca

 

[RobbieD]

I tried to use the connector that was originally in it and it worked pretty well until the wire came out again. One thing I was wondering and wanted to ask if there any place I can get these actual pens that go into connector that are the exact same kind that Ford made them or is there are some other kind of substitution

The gray plastic connector body itself is broken. Besides the locking tabs on the outside to keep the connector set mated, your biggest problem is that the terminal locking "fingers" are broken inside some of the cavities. The tips of these fingers go into a groove in the metal terminal, or "pin". Without the finger, there's nothing to lock the pin in the cavity.

The plastic used in these older connectors is extremely brittle and they commonly break. I do not know of a source for exact replacement parts. On these older trucks, certain parts in general are getting hard to find, and we just gotta be creative.

@Angie 's suggestion is a good one, or something I do on occasion with a broken connector, is mate the two connectors, push in on the wires to make sure that the two terminals are fully seated, then fill the cavity from the rear, around the wire, with hot glue. Done right, when it hardens it centers the pin and keeps it from backing out.

For the broken external locking tabs, you run a tie-wrap around the mated connectors to keep them locked.

what should I use a maxi fuse or can I use fusible link wire that u can buy from advance and autozone?

Dealing with fusible link wire is such a pain in the ass.
In my '84 I replaced the fusible link with a Maxifuse, using a Scosche holder to end up with this, in place of the fusible link:

Thanks for adding your pics; it helped a lot to see what you're dealing with.

Good luck!