Using a 40 amp fuse instead of a FUSE LINK does not carry enough amps for alternator.--Install a proper FUSE LINK WIRE--CARQUEST carries them premade--If you are not sure how to do this, consult with a GOOD auto-electric shop.--ask around.
Replace the battery
or the alternator is producing AC and not DC ie its rectifier has failed
You have a dead short in head lt wiring. try un plugging one head lt at bulb at a time. if continues to blow fuse inspect wiring in cicuit for any bare wire too frame.
SOURCE: Fusible Links on 1972 Ford F 250 PU
follow the wire where you think the link may be, and and where the large bulge is, is where the link usually is, now the fuse is not usually non-replaceable, so you can go to a parts house and get an aftermarket fuse link that can easily be installed. take the voltage regulator with you and have it tested to insure it was not damaged.
also check all fuses in the fuse box. and the link on the main wire on the back of the alternator.
SOURCE: 1995 Dodge Neon
the daytime runnling light module is in the dash under cigarette lighter i got my module for 10 bucks at a junk yard
SOURCE: 97 dodge dakoata main fuse keeps blowing 140 amp fuse
Regulator in alternator obviously faulty, have it bench tested & fixed or replace alternator, and cure your problem.
SOURCE: blows fuses
SOUNDS LIKE THE ALARM HORN IS SHORTED, CAUSING FUSE TO BLOW.
TRY UNPLUGGING ALARM HORN & SEE IF FUSE STILL BLOWS.
IF IT DOES NOT BLOW, REPLACE ALARM HORN.
SOURCE: Headlights quit working, no low or highbeams, only
Could be a short or sensor in the headlight switch causing it to:
a. just not work
or
b. get too hot and melt the contacts until they cool
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