1989 Trooper Main Fuse

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1989 Trooper Main Fuse

Postby HippyPants » Mon Mar 20, 2017 4:39 pm

Hey guys, I'm looking at a friend's 89 Trooper right now and am trying to find the main fuse. As far as I can gather I'm looking under the dash on the driver side somewhere around the speaker, but I'm not even completely sure what I'm looking for. What type of fuse is it? Is it in some kind of closed holder? Does anyone have a photo of it and it's location that they could help me out with?

Many thanks,
Jason
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Re: 1989 Trooper Main Fuse

Postby HippyPants » Wed Mar 22, 2017 3:41 pm

I figure I should give a little more information as to the ongoing problem in case anyone can give me some insight. So it's a 1989 Trooper with the 2.6L engine and 5-speed. It has been sitting for about a year now without running and I'm planning to buy it if we can get it running. Before it was parked it was working fine overall, although it had some fuel pump electrical issues. My buddy fixed that problem and had it running great, but here is where the current problem started. I guess as he was closing the hood a wrench fell that he thought was put away and landed across the terminals of the battery. There was a big "Pop" and it was dead. He didn't put any effort into figuring it out at that point and it sat in his driveway until now. The battery is totally dead so I'm going to replace that, but I need to figure out what went "Pop". Our assumption was the main fuse, and so that's what I'm currently looking for. I can't seem to find any clear directions for where to find it, though, just that it might be under the dash on the drivers' side. I know there's the fuse box under the hood, fuseable links around, I'm just not sure where to look first. All fuses in the fuse box seem in tact.

Any help would be appreciated!

Jason
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Re: 1989 Trooper Main Fuse

Postby MarkB.NV » Thu Mar 23, 2017 4:03 pm

Hi Jason ... Welcome to the Planet!

There are several "fusible links" in the front right corner near the battery and the RHS headlight. These look like a 3 inch section of shielded wire and have spade connectors on either end, and can easily be removed/replaced ... Carefully since the beast is nearing 30 years old.

Simple to test each with your multi meter set to ohms. If a fusible link is good, it will read about zero ohms. If bad, it will read like open circuit -very high ohms/resistance.

There is a PDF copy of the 1988 factory service manual floating about and that should have parts of the wiring diagrams. Easy to find with good google fu.

There may be additional damage cause by the errant wrench, but you'll be on the right path at least.

Also, always OK to post a sh.t ton of pics of your new found truck. We do appreciate more Trooper porn. :)
MarkB.NV,
Tan 1986 Trooper, 2.6 / 5 speed, 173K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=101538

White 1984 Trooper, 1.9 / 4 speed, 89K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=85764

Sold ... Silver 1990 Trooper, 4 cyl, 5 speed
Sold ... Blue 1989 Trooper, 4 cyl, 5 speed

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Re: 1989 Trooper Main Fuse

Postby HippyPants » Mon Mar 27, 2017 12:34 am

Thanks for the reply and ideas, Mark; it's much appreciated! I do remember seeing the fusible links by the battery, but didn't test them. I think I'll walk over there tomorrow and have a look with the multi meter. Also, thanks for the note on the '88 service manual, I'll go find that and have a look through.

Best regards,

Jason

PS. I'll be sure to snap a photo or two tomorrow :)
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Re: 1989 Trooper Main Fuse

Postby HippyPants » Tue Mar 28, 2017 3:03 pm

So I got out to the Trooper today and tested the fusible links as you suggested. The three smaller ones tested minimal resistance, but the largest one on the end (black) gave no change in reading when probed. Then I noticed that it actually felt broken in one place. Hopefully that link is my only problem! I'm off to Lordco to see if they happen to have fusible links there. From another thread it looks like the black one might be 26 amp. Should this be a pretty generic part?
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Re: 1989 Trooper Main Fuse

Postby HippyPants » Tue Mar 28, 2017 5:35 pm

Well, I managed to make a new fusible link with fusible link wire from the parts store and reused the connectors from the old burnt out one. She's alive now!!! We took her for a drive up a snowy logging road on the mountain that is my backyard and she handled beautifully. She's got many quirks that I'll have to get to know, but I'm really excited. Picked her up for $500 CAD (375 USD) which I'm pretty happy about.

Thanks again for your help, Mark, you put me on the right path.

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Re: 1989 Trooper Main Fuse

Postby RickP » Tue Mar 28, 2017 8:42 pm

Awesome!
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Re: 1989 Trooper Main Fuse

Postby MarkB.NV » Wed Mar 29, 2017 12:59 am

The Planet is an awesome place ... the we are much smarter than I.
MarkB.NV,
Tan 1986 Trooper, 2.6 / 5 speed, 173K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=101538

White 1984 Trooper, 1.9 / 4 speed, 89K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=85764

Sold ... Silver 1990 Trooper, 4 cyl, 5 speed
Sold ... Blue 1989 Trooper, 4 cyl, 5 speed
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Re: 1989 Trooper Main Fuse

Postby HippyPants » Thu Mar 30, 2017 1:50 pm

I snapped a few pics during the making of my new fusible link. It was the large black link by the battery that tested as an open circuit. I could actually feel the break in the wire through the insulation and shielding. I picked up an 8 inch or so section of 16 gauge fusible link at the local parts store and it came with two solderless connectors that I ended up using to connect to the old end pieces. My tools were in the Trooper at my buddy's place, so I made do with just my Leatherman Wave. Wire strippers, knife, and the pliers were all I needed.

Image

I cut through the white insulation on the ends, pulled off the weaved sheathing and the old link fell apart where it had burned out.

Image

I cut a section of the new link, stripped the ends, slid the weaved casing over it, and crimped them into the blue connectors. I then connected these to the wire ends coming from the original link's end connectors.

Image

Image

Maybe not a pretty job, but once installed along with an extra battery I had, the Trooper began turning over! It had sat for 8 or so months, I think, but with a little coaxing she fired up!
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Re: 1989 Trooper Main Fuse

Postby MarkB.NV » Thu Mar 30, 2017 9:09 pm

Nice write-up Jason.

I did not know they sold the wire in generic lengths.

Were there different sizes (thicknes)as well?
MarkB.NV,
Tan 1986 Trooper, 2.6 / 5 speed, 173K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=101538

White 1984 Trooper, 1.9 / 4 speed, 89K mi.
http://forum.planetisuzoo.com/viewtopic.php?f=15&t=85764

Sold ... Silver 1990 Trooper, 4 cyl, 5 speed
Sold ... Blue 1989 Trooper, 4 cyl, 5 speed
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Re: 1989 Trooper Main Fuse

Postby HippyPants » Thu Mar 30, 2017 9:32 pm

Yeah, they had it in a few different gauges. I had found from another thread that I needed a 1mm^2/16ga fusible link wire and it was labeled as such. They didn't have it at the Canadian Tire auto section, but Lordco had it on the shelf.
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Re: 1989 Trooper Main Fuse

Postby itsmehb » Wed Apr 05, 2017 6:47 am

HippyPants wrote:Yeah, they had it in a few different gauges. I had found from another thread that I needed a 1mm^2/16ga fusible link wire and it was labeled as such. They didn't have it at the Canadian Tire auto section, but Lordco had it on the shelf.


For those who read this and say Lordco, what's that, like I did. Lordco is the largest automotive distributer of parts in British Colombia, much like Napa may be here in the states. My thanks to google. And my thanks to you for this write up as it may be helpful in the future for someone.
1990 Amigo, 2.3 5 speed (sold)
1991 Pick up (long gone)
2000 Amigo, 2.2 5 speed(sold)
1985 Trooper 1.9 4 speed (sent back to KS)
1989 Trooper RS 2.6 5 spd. Red

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Re: 1989 Trooper Main Fuse

Postby Skeletor » Tue Apr 11, 2017 10:14 am

HippyPants wrote:Well, I managed to make a new fusible link with fusible link wire from the parts store and reused the connectors from the old burnt out one. She's alive now!!! We took her for a drive up a snowy logging road on the mountain that is my backyard and she handled beautifully. She's got many quirks that I'll have to get to know, but I'm really excited. Picked her up for $500 CAD (375 USD) which I'm pretty happy about.

Thanks again for your help, Mark, you put me on the right path.

Image



nice photo......wow, chrome front bumper ? nice, very nice....
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