Fusible link failure Toyota Hilux 1990

I have a 1990 Hilux diesel truck and recently the alternator started
intermittently failing, probably the brushes. The garage recommended
replacing it but had problems installing it as it had an internal
voltage regulator whereas the old one had an external. Consequently
they got an auto electrician to do the installation.

Subsequently on a long journey at relatively high speed at night the
lights suddenly went bright. Being naive I thought "Oh good I can see
better" but about 20 minutes later there was a loud bang and much
rattling. So I stopped.

It turned out that the fusible link had blown causing the wipers to
operate (the rattling) but much additional damage was done including
blowing the regulator, the tacho, all parking lights, the dashboard
illuminator and the immobiliser as well as stripping the splines on the
wipers.

The auto electrician at the place I am staying was very good and
replaced the regulator under its warrantee but I still have to get the
other damage repaired.

I have three questions:

1) What could have caused the fusible link to blow?

2) Having replaced the link but not knowing the cause of the failure is
it likely to occur again?

3) Do I have a reasonable claim on the garage that fitted the new
alternator?

I would very much appreciate any advice you can give me

Thanks

Jeremy

Hi Jeremy I am a auto elec also
1 Fusible links should only blow when a rated current is exceeded this rated
current can be derated if the fusible link is slightly corroded or cracked
this can happen if the link is aged, as 16 years will do.
2 If an aged link is the problem just replacing the link after the
subsequent damage is repaired should be ample.
3 The garage wouldn't have had any idea about the fuse condition it is not
that common a fault and they are probably just mechanics.
You don't mention how long between fitting and reg failure, if a day or two
you might have some recourse if longer I think you have no hope, another
possible scenario is that the reg went short and charged flat out and then
the fuse blew it is a which came first the chicken or the egg case though.
Joe



"Artist" <jeremyholton@gmail.com> wrote in message
news:1140740754.233357.109100@i39g2000cwa.googlegroups.com...[color=blue]
>I have a 1990 Hilux diesel truck and recently the alternator started
> intermittently failing, probably the brushes. The garage recommended
> replacing it but had problems installing it as it had an internal
> voltage regulator whereas the old one had an external. Consequently
> they got an auto electrician to do the installation.
>
> Subsequently on a long journey at relatively high speed at night the
> lights suddenly went bright. Being naive I thought "Oh good I can see
> better" but about 20 minutes later there was a loud bang and much
> rattling. So I stopped.
>
> It turned out that the fusible link had blown causing the wipers to
> operate (the rattling) but much additional damage was done including
> blowing the regulator, the tacho, all parking lights, the dashboard
> illuminator and the immobiliser as well as stripping the splines on the
> wipers.
>
> The auto electrician at the place I am staying was very good and
> replaced the regulator under its warrantee but I still have to get the
> other damage repaired.
>
> I have three questions:
>
> 1) What could have caused the fusible link to blow?
>
> 2) Having replaced the link but not knowing the cause of the failure is
> it likely to occur again?
>
> 3) Do I have a reasonable claim on the garage that fitted the new
> alternator?
>
> I would very much appreciate any advice you can give me
>
> Thanks
>
> Jeremy
>[/color]

Thanks Joe, that's very helpful. So its impossible to determine
whether the fuse or the regulator initiated the problem. As the
supplier of the alternator has agreed to replace the regulator under
warrantee I guess it means that to some extent they are accepting that
their equipment could be the cause.

The garage have told me that they will try to recover my costs and fix
the remaining problems under the supplier's warrantee but I am not
optimistic about getting any money back.

Jeremy

Sounds like they are doing the best that they can, I hope things work out
your way.
Joe