Ford D9ZZ-14526-H Circuit Breaker Assembly

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Bypassing the fuse with metal or foil can cause serious damage to the electrical system.

In addition to fuses, the wiring system incorporates fuse links for overload protection. These links are used in circuits which are not ordinarily fused. Fuse links are several wire gauges smaller than the circuit they are incorporated into and can be identified by their green or black color and molded color identification tag. The tag colors and corresponding gauges are as follows: green - 14 gauge, orange - 16 gauge, yellow - 17 gauge, red - 18 gauge, and blue - 20 gauge. It is important to note that fuse links cannot be repaired and must be replaced with a new fuse link of the same gauge, length, and insulation. To replace a blown fuse link, the battery ground cable should be disconnected and the damaged fuse link or fuse link eyelet terminal should be disconnected from the battery terminal of the starter relay. The damaged fuse link should be cut from the circuit and discarded, and the insulation from the circuit wire should be stripped back approximately 1/2 inch from the cut. The proper replacement fuse link should be determined and crimped into place in the wiring circuit, with any necessary eyelets being cut off. A resin core solder should be used at each end of the new link to ensure a good solder joint, and plenty of electrical tape should be used to cover the soldered joint to prevent any exposed wiring. Finally, a fuse link should be connected at the starter solenoid, the battery ground cable should be reconnected, and the circuit should be tested for proper operation.