On the '94 Safari/Astro there is a connector with 4 fusible links coming out of it that plugs into a distribution block on the firewall behind the battery. The C and D link contacts got hot enough to melt the plastic around them and the C circuit opened, causing the truck to stall and a bunch of accessories not to work.
I just replaced the connector, splicing in two of the fusible links that came with the replacement and transferring the two undamaged ones to the new connector body.
Everything works again, but I have some questions:
Is it normal for fusible links to become warm under heavy load? How warm?
With the engine running, headlights, dome lights, reading lamps, and blower on, it took about 5 minutes before I could sense that the C and D fusible links were warm to the touch. After 10 minutes it was a little warmer but still not anything I'd be immediately worried about. Still, a couple of hours driving on a hot night with the headlights and other accessories on could be another matter?
Should I be concerned?
Also, are their any special tools, probes, shunts, or other tricks that would make checking current draw through different fuses easier?
Thanks,
Mike D.