No, not for fusible link. Crimp.


I haven't priced fusible link, but I'm sure it's the lowest cost option.

However, take a look at a mega fuse as well. A Blue Sea holder and a 140 amp fuse would set you up nicely. Maybe it's in the budget.

 

I have a second battery installed off my starting battery. After replacing the stock alternator cable with some 1/0 I installed a mega-fuse for the alternator in front part of the PDC.

Total cost was $5.00 for mega fuse plus a couple bucks for 1/0 alternator cable and connectors.

Stock XJ's aleady have a mega fuse holder on the front of their PDC. After a little grinding and fitting a second bolt with washer opposite the alternator bolt, the mega-fuse fits perfectly. The stock pdc connection cover fits over the mega fuse.

So far hasn't blown or caused any problems. When looking at Mega Fuses there are several types, some are rated as "slow blow, while others have faster blow ratings.

 

My concern in using a fusible link is my intended method of "coupling" them. Would ring connectors on a post be acceptable?

 

Nope.

 

Yep.

 

I would not use a standard ring connector on a fusible link. Some are manufactured that way, as here, but that's not a standard connector.

The usual method is to use a parallel or butt connector.

 

I agree with everything here except the butt connector. Never use a butt connector under the hood of a car.

 

Could you explain how this setup (pic) is supposed to work.


Is that the battery (+) cable and the alternator (+) cable joined together?


How did you plan on connecting a fusible link in this configuration?

 

My plan was to use 4awg cable from the alternator to the distribution post which I'd mount close to the PDC. The fusible link would come from that distribution post to the PDC.....

 

Why do you want a fusible link there? There is a mega fuse in the PDC between the Battery and the "generator" (alternator) terminals, isnt' there? Or did that go away by 1999?

 

I don't know about previous years but 99's have a fusible link on the alt to PDC.

 

no. It's from PDC to battery (the thin green wire)

 

Diagram for a '99 XJ shows the placement of the fusible link in the charging system. The dark horizontal line at the top of the diagram is the bus bar at the end of the PDC.

 

I don't think you want the red cable (battery (+) ) connected to the black cable (alternator (+) ), like you show. The red battery cable should go directly to the PDC bus bar and the black alternator cable to the distribution post, coupled with the fusible link on that same post, then to the PDC.

 

My 98 had a fusible link from the alternator to the right post on front of the PDC. After removing the fusible link and installing the missing left mega-fuse post (earlier XJ's using a mega-fuse came with both the left and right mega-fuse posts. I ran a 1/0 cable from the alternator to the left side of a mega-fuse and another short 1/0 cable from ther right side to the battery.

alternator ===1/0==> (left post) __ megafuse__ (right post) ==1/0==> (battery)

For me this was less difficiult then trying to splice the correct size fusible link into the 1/0 cable from the alternator.

The 1/0 circuit sometimes used to charge both batteries, poduces a slight alt. charging improvement, the alternator seems to be able to maintain 14 volt charging a little better under various conditions than the stock alternator cable when charging the starting battery or both batteries.

The 1/0 cable is also used sometimes start and run the engine from the auxillary battery, using a 200+ amp manual swiched installed near the aux. battery.

If I were going to install a fusible link on a 1/0 or other size cable I would most likely install it to a ring terminal near the end of the alternator cable that connects to the battery or PDC. Some people move their alternator cable so it connect directly to the battery rather than the PDC.

I would think the fusible link after the strands are meshed to the cable can be soldered to the alterator cable and crimped and/or soldered to a ring terminal.


(alt ======= (meshed/soldered) ===== fusible link ===== (ring terminal)