Fusible Link - Service Repair Kit

NO. 86/12/94/US

DATE: 02/12/94

MODEL
Range Rover

AFFECTED VEHICLES
Range Rover from LH 610295 to LH 647644

SUBJECT
Fusible Link-Repair

DETAIL

From LH 610295 a design change introduced a new electrical harness which included a number of fusible links in close proximity to the battery. A number of reports have been received which have indicated that when a fusible link fails a replacement link is sometimes difficult to obtain and necessitates the replacement of the complete harness. To overcome this difficulty a service kit has been developed which includes all the fusible links attached to the battery cable and allows a cost effective repair to be carried out.

The installation of this kit should be carried out by a qualified Land Rover Technician.

ACTION REQUIRED

Upon failure of a fusible link first locate the cause of the failure and repair as necessary. Replace the failed fusible link using the service kits identified below.

PARTS INFORMATION

AMR 3928 Range Rover kit

A suitable crimping tool can be obtained from Radio Shack-Part # 64-410

PROCEDURE






1. Disconnect the battery positive and negative leads.
2. Locate the fusible links in the positive battery lead, covered by an expandable gauze sleeve.
3. Remove the tape wrap from the gauze sleeve and cut the gauze from the harness to expose the fusible links.

NOTE
Range Rover-has 8 - 1 mm and 2 - 2 mm fusible links and each link should be carefully matched by cable size to the main harness.

4. Cut each positive lead adjacent to the existing splice joint (on the main harness side of the splice). Ensure the cut is made through cables that are in good condition.






5. Fit the large gauze sleeve to the main harness and push back until the harness leads are exposed.
6. Trim back the insulation on the main harness leads 6 mm from the cut end.
7. Ensuring that the new fuse link selected matches the size (diameter) of the old, cut the new fusible link to a length appropriate to the positioning of the new individual splice joint. Trim back the insulation on the fusible link to 6 mm from the cut end.
8. Cut suitable lengths of gauze sheathing (to cover the complete length of the fusible link) to replace any damaged individual gauze sheaths and push back over the fusible links.
9. Fit a heat shrink sleeve over the individual main harness leads.
10. Using the inline splice overlap and crimp the individual fusible link to the appropriate main harness lead.
11. Solder the crimped leads together to provide a secure joint.






12. Position the heat shrink sleeve over the spliced joint and using a heat gun shrink the sleeve over the crimped/soldered joint.
13. Pull back the individual gauze sleeve to cover the full length of the fusible link.

NOTE
Repeat operations 1 to 13 for the remaining fusible links.






14. Pull back the large gauze sheath to cover the complete length of the link and securely tape the ends of the sheath to the main harness.
15. Reconnect the battery and re-input the radio security code.

WARRANTY
Normal warranty policy and procedures apply.

COMP. CODE
7Y1T

SRO
88.15.89/26 Replace fusible link 00.40 hour