Damage to 175A Battery Harness Fusible Link

There have been a number of warranty claims for battery harness replacements in which the 175A fusible link has been reported as either an intermittent connection or has failed.

After extensive analysis of returned parts, it has been determined that a current in excess of 175A has passed through the harness causing the fusible link to blow. Tests have confirmed that this failure mode can be reproduced by using the positive connection to the underhood fusebox as a jump start connection (refer to the photograph below).

The underhood fusebox positive connection should NOT be used as a connection during jump starting as this allows the starting current, which can be in excess of 200A, to pass through the harness containing the 175A fusible link.

Correct jump start connection posts are clearly identified in the owner handbook (page 6-17). Damage to the fusible link caused by incorrect jump starting procedure is not covered by warranty and is considered to be a retail repair.

Where required, please advise the customer of the correct jump starting procedure.