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Old 08-19-2005, 11:14 PM   #8
bluesteve
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Join Date: Aug 2005
Location: Stockton, California
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Re: 95 Astro turns over, won't run, no headlights

My '95 did the same thing. A mechanic pointed out the somewhat melted connector and tried to tell me it was caused by the fuel pump drawing too much current. He explained that the resistance in the pump was high. I should have known better. Anyone with basic electronics knowledge knows that a component with higher than normal resistance draws LESS current, not more. But like a fool, I let him replace the fuel pump for over $600.00 and , of course, the damaged connector and the fuseable link which had blown. Very soon it did it again. I took it to an automotive electrical shop. They simply replaced the link again and said it should be fine and that the current draw thru the link was normal. They charged me over $150.00 for this. Within 2 months it blew again. I didn't bother to look at the connector. I simply cut the fuseable link out of the circuit and replaced it with a wire of the appropriate guage (I used 16 guage) and an in-line fuse holder. The original fuseable link was rated at 20 amps. Since it was blowing easily, but not constantly, I tried a 25 amp fuse in the holder. While this fix isn't perfect (no one seems to know why, occasionally, the circuit draws too much current), it has made my van reliable. It does blow about twice a year (once it did it while trying to leave from a red light. A bit embarrassing, but it was fixed and I was under way in under 30 seconds), but instead of calling a tow truck, I just pull over, open the hood and change the 25 amp fuse and I'm on my way. It's been like this for 4 years now. Try it, you'll like it. :smile:
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