Repairing a Ford ignition wire fuse, more commonly called a fusible link, is the last step in servicing a Ford vehicle that has burned this wire apart. If it is repaired before determining and repairing the cause of the problem, the fusible link will burn again. Start with a visual inspection of the engine wiring, followed by a close inspection of the ignition switch wiring. Make any necessary repairs, then install a new fuse link.
Raise the hood of the car and follow the positive battery cable to the fender mounted solenoid. The solenoid is a round, plastic switch that has red battery cables attached to the main terminals and smaller wires installed on smaller connectors. Part of the wires that are bolted to the main connector are fusible links. They have a softer, thicker insulation. These are designed to burn apart in the event of a short circuit.
Inspect the wiring under the hood. Look for chafed wires, flaking insulation or wires laying against the exhaust manifold. Older vehicles may experience a number of wiring problems due to the engine heat causing the wiring to deteriorate. Replace any suspected wires and connections that show signs of decay. Use wire strippers and a crimping tool to make these repairs.
Inspect under the dashboard. Look for wires that have rubbed against the steering column or column mounting bracket. On older vehicles, the wire retainers may loosen and let the wires sag. These can easily be damaged. Make any repairs necessary.
Replace the fuse link wire. Replace the link with wire that is rated according to color code. Use wire cutters to cut out the burned section and strip one-fourth-inch of the insulation off both the existing and the new wire. Insert a new section of wire, and crimp new connectors in place.
