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Hey folks, I have been trying to troubleshoot an electrical issue and I wonder if anyone has any advice. I have an 82 4wd with a 22RE transplant. In a nutshell, they did a real hack job on the wiring. It's run great despite that, but I recently put on a new alternator belt and also discovered I had no electricity at all at one point, so I solved that by desoldering a broken wire coming off the pos terminal of the battery. However, now I have discovered I have no headlights (neither side, neither hi or lo beam), no horn, and no emergency flashers. I do have everything else, including turn signals, and the truck runs fine otherwise.
In my efforts to trace this, I have found:
1. Both headlight and taillight relays work. They both click on the first position of the light switch, but there is no relay click on the headlight position of the switch
2. There is no voltage at the headlight connection
3. Fuses are all ok, though there is no voltage at the horn or headlight fuse connections
I'm sure this all relates to my reconnecting that wire, but as I said the wiring is a real hack job. I have the FSM and looking at the wiring diagram, I see this clue:
There is a wire (RL) coming from the headlight relay that joins to the fuse for the haz/horn and this RL wire goes to a fusible link (P) just before connecting to the battery. So, this makes sense because it is these three components that have no power. However, I cannot yet find that RL wire in the vicinity of the battery, nor do I see any fusible links around the battery.
Has anyone else encountered this situation with an 82 and if so, any advice?
I had the same exact issue -it’s an issue w the fusible link. Which is just a wire on these trucks. I had the same problem. You can get the link at Napa, they had to order it it for me if I remember correctly. The 3 wires in the blue circle are the links. You’ll notice one of them is mated to a second circuit (green circle). I don’t have my wiring diagram in from of me to give you the link value
If not hacked up to bad, you should have 3 fusible links coming off the battery. One goes to the headlight relay and Hazard/Horn fuse via a Red/Blue wire.and the link is Green for 40Amp circuit. Another Green Link is for the power to the ignition switch via a Black/Red wire. Another is a Red link for 50A circuit that powers the Stop light, Tail light and Heater.
Excellent guidance, thank you! I found the RL wire to the battery terminal, and it's connected via one of those green connectors. I checked voltage on the male plug while plugged in and nothing. So, I bypassed and went direct to the battery terminal with the RL wire and problem solved. SO, the next question is, how to get it back together with the fuse protection? I'm thinking of getting some fusible link wire (not sure what size/value; the wiring diagram just says G?) and connecting it with the RL wire, and reusing the green connector. Will that work?
You will find that auto store will have packaged fusible link with two different descriptions. For your circuits you will need either Green colored link wire or one that protects a 40 circuit (Shown on package as 40 amp), usually about 7-9" length. Put the appropriate ring connector to fit the battery post, and a heat shrink/sealer butt connector on the other end. Much like what is posted in Toy Tek pics above. Same goes for the 50 amp circuit but wire is Red rated for 50 amp circuit
06-06-2018, 07:50 PM
