It appears that the fusible link from my alternator to the starter has worn through the insulation and shorted on the oil dipstick tube. Must have been rubbing for awhile. I have temporarily run a 10 gauge wire from the alternator to the starter so that I could get to work today but I definitely want to fix this the right way.

Does not appear to be a wire that is sold by itself. Looks like I'll have to buy some fusible link and solder it into the original wire. Can anyone tell me what gauge that OEM fusible link is?

 

A 5amp fusible link spliced in will do

 

you mean like the holders that are prewired for bladed fuses that go in the fuse box? The gauge wire on those things don't seem thick enough for this application. I did find 10awg fusible link on amazon but if you think a 5amp fuse holder would do the trick I can get that tomorrow.

 

Not all of them are fusible links.
Maybe a boneyard?

 

I'm just going to make a new one. I'm getting 10awg fusible link and will cut the old length out from the OEM 8awg wire and solder the new length in. From what I read, it should be 2 sizes smaller so 12awg is what should be used for the link. The OEM fusible link says 5.0 sq mm. When i search that on amazon it comes up as 10awg fusible link.

Oldblue, i'm curious as to how a 5 amp fuse wouldn't blow on a 130 amp alternator charging wire. Maybe we're misunderstanding eachother.

And while we're talking about fusible link, what means of protection is on the thick red positive wire that runs all the way from the battery up to the post on the under hood fuse box? Is there a fusible link somewhere hiding on that wire because from the looks of it, that's a straight run of hot wire. Why would GM be so worried about fusing the charging wire from the alternator to starter (besides crashes) but not the positive wire from all the way in the back?

 

There’s a 50 amp fuse back by the battery for the BCM . The red wire that goes from the positive battery terminal to the under hood fuse box is direct , no fuse. Your method of soldering in a new fusible link will work.

 

The shop manual only describes what a fusible link is, it does not mention where any might be in the car.
GoOgle says: part # 88953221, 84082836, or 15319480 none of those links show a fusible link they are the maxi fuses. I don't think GoOgle is a good source.

I found something at GMPartsGiant https://www.gmpartsgiant.com/oem-che...ery_cable.html Seems to be 2006 only, might be solid gold.