Replacing a fusebox? (S2 2000TC)

[Willy Eckerslyke]

Just wondered if anyone has any advice about replacing the standard fusebox on a Series 2 2000TC with something more modern?
Searching old posts, I've found a few discussions but nothing recent or very specific.

I had a bit of a scare this morning when the wipers slowed to a crawl, then stopped altogether and a burning smell issued from behind the glove box. It transpired that the fuse was loose so had become hot. I've now pinched the fuse clamps tighter together and also replaced the wiper motor and rack with a healthier one - the old rack's pivots all felt worn and loose so may have been putting a strain on the motor. But having seen how easily the standard fuse box can overheat, I'm keen to replace it with something safer.
So any pointers gratefully received.

 

[keanej]

I would make sure you have long fuses, 32mm, there are some which are only 29mm or shorter and therefore don't make contact along the full length of the clamps

 

[chrisyork]

The subject of the S2 fusebox is done to death elsewhere on the forum. What I mean by this is the fuse box type that has a nice labelled cover and lives in the passenger glovebox. Early S2 cars actually have many S1 features, including the wiring and fuse box layout, so these are not affected.

The "S2" fusebox is used without apparent problem in the P5B, so there is clearly something odd about its installation in the P6. There seem to be three funadamental problems. First, the black plastic of which it is made has a very low melting point - and a correspondingly very low flame point!! In English that means you risk having your car set on fire if there is any problem in the fuse box Next, it is possible to use metric fuses, which are slightly shorter than the correct imperial ones and have been known to cause overheating of the terminals. Finally, it seems that the loom manufacturer didn't always get the crimping of wires to the fuse terminals as tight as they could be.

All the above taken together make the S2 fuse box extremely vulnerable to the most minor of problems.

The fuse box is extremely difficult to replace in the S2 layout - but, as the above emphasises, it's well worth the effort! I'm afraid it's really a young mans job, as it involves intricate work - thanks to very short lengths of wire once you've cut the old box out - lying on your back half in and half out of the car and, to put the seal on it, too many wires and the need to get them all in the right order. By comparison the choice of new fuse box is a very minor concern. As long as you have at least as many fuses as the original you'll be OK, and they are widely available serving the kit car fraternity.

Time to GALMI (my ex wifes upmarket acronym for Get A Little Man In - Sorry ). Check in the yellow pages for a mobile auto electrician.

Chris

 

[Willy Eckerslyke]

You've just confirmed my fears Chris. I was rather hoping someone would have a magic formula, but sometimes the hard way is the only way. I do have a spare loom with fusebox still attached so will have a good look at it this evening to see if inspiration dawns. Perhaps it'll be less of a struggle to fit two seperate new fuseboxes instead of a single one.
I'm a little averse to paying someone else to do the job...

Re: fuse lengths. The problem was actually caused by an odd one that was too long, so not making full contact, but when I replaced it with the correct size, the loose 'clamps' only provided intermittent contact - enough for the indicators, but not the wipers. This confused me into replacing the wiper motor and rack, then examining the switch, before having another look at the fuse.