bofus Posted July 20, 2008 Report Posted July 20, 2008 Just doing some last minute checks before going to France on Tuesday, finishing trailer socket wiring, oil change and fluids check. Just about to take a 12v feed from the battery, when I noticed the small junction fusebox was absolutely red hot, lifting the lid, the 110 Amps fuse although not blown was nearly melted and the cable that feeds the main fusebox very charred.Doing a search this appears to be a common problem.....:-( I need to get this sorted by Tuesday am at the latest. Ford, Seat or VW which dealers are likely to keep stock or are there alternative ideas to overcome the fault. I was planning on swapping the fusebox and re-terminating the cable... Gav Quote
geoffc Posted July 20, 2008 Report Posted July 20, 2008 I would say VW are the most likely to have stock....at least the fusebox in not expensive! If the cable has been over heated at the end, it will be better to replace the entire cable. The old cable, if repaired, will most likely overheat again. Quote
mumof4 Posted July 20, 2008 Report Posted July 20, 2008 yup geoff....the fusebox is around 20 quid, cable should be peanuts and is recommended to be replaced at the same time, as it can happen again if not. Quote
bj2004 Posted July 20, 2008 Report Posted July 20, 2008 make sure any crimp connections and other contacts are tight as if not at the current passing through them they will just get over heated again Quote
Willie Krashitt Posted July 20, 2008 Report Posted July 20, 2008 And as BJ said, make sure that the crimped terminal on the main loom is good, or you may find (as I did) that the new fusebox will be melting very soon. I had to cut about 4" from the main loom before I found non charred wire. Added a new piece of cable and a new terminal and has been ok since Dec '06.Heorge. Quote
mikej Posted July 20, 2008 Report Posted July 20, 2008 Been there , had it , done as suggested new box and cable , make sure the new nuts are tight and job done been fine ever since . Found vdub cheaper than fords in my case ..... :rolleyes: Quote
bofus Posted July 20, 2008 Author Report Posted July 20, 2008 Looking at some other pics it appears to the feed to the main fuse box (called the junction box on TIS) as apposed to the alternator loom. The alternator loom is fine, but the 16mm2 cable to the junction box is toast. At this late stage Ive gotta hope that a local stealer has one in group stock AND that will cure the problem. Does anyone know what causes the crimp to get hot? is it a bad connection to start with OR is it close to overload OR does it age? Going on my normal 16th / 17th edition knowledge, 16mm2 is only good for about 95 Amps, I may grab a current meter and measure what is actually going down that cable!! More later, when I ring around the local stealers to see what they can do :-) May have to use one of the other vehicles in the fleet, Frontera diesel, Vectra Petrol, Vectra Diesel or Westfield....sod the caravan, back to France in the Westfield....shame the kids wont fit either :-) Quote
Willie Krashitt Posted July 21, 2008 Report Posted July 21, 2008 I'm pretty sure that the cable from battery to the auxiliary fusebox comes with the new fusebox. If the damaged cable is the one in the main wiring loom (goes off into main loom above nearside headlight) then surgery will be required. The main loom, of which this is a part, is over Quote
mikej Posted July 21, 2008 Report Posted July 21, 2008 Quote : I'm pretty sure that the cable from battery to the auxiliary fusebox comes with the new fusebox.It does indeed come with the new fuse box.... Quote
bofus Posted July 21, 2008 Author Report Posted July 21, 2008 New fuse box fitted after buying all the stock at the local Ford dealer (2 off) none of the VAG garages had any in stock. Ford dealer (whom i know the parts guy quite well) says they sell about 15-20 a year and it seems to be increasing each year I have cut back about 4" of cable that was charred, a 16mm2 butt crimp from the local electrical factors, loads of heatshrink and a new terminal (slightly filed to fit) seems to fit. BUT i have lost the piece of paper that told me the order of the red/white, red/black and red wires into the junction box....feck!!! Gav Quote
bofus Posted July 21, 2008 Author Report Posted July 21, 2008 Bad form to reply to oneself.. Now all sorted, a quick check on TIS and a confirmation of some photos on here I have got it all back together. Even after 10 mins of running, the terminal is stone cold, but the alternator lugs are slightly warm at each end...another job another day!!!! Thanks to all for their help and advice. One Question? What is the connector at the other end of the main feed cable, where does it terminate and does it suffer from the same problems? Gav Quote
Willie Krashitt Posted July 22, 2008 Report Posted July 22, 2008 As far as I can work out, the main cable from the aux fusebox going into the vehicle loom is initially spliced into 3x 6mm2 cables somewhere above the glovebox. These go variously to the main fusebox, the ignition switch and via more splices other places as well. I have never heard of anyone having problems with larger sized cables inside the car. Have a nice holiday,George. Quote
mikej Posted July 22, 2008 Report Posted July 22, 2008 Did you change the main cable from the alternator at the same time , i hope so or you will no doubt be purchasing another fuse box very soon lol.... :23: Quote
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