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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 24
 1997 Defender 110 300 Tdi CSW Rioja Red
Fusebox

Click image to enlarge
How hard/easy is this to fix. Once I find the fault/cause for the melted fuse and holder.

300tdi bulkhead fusebox. 7.5a for lhs headlight.
Post #1045637 12th Sep 2024 2:38pm
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Roverdrive



Member Since: 11 Aug 2024
Location: Wirral
Posts: 10
United Kingdom 
That is likely caused by a poor connection between the fuse and the terminals.
This leads to heat and melted stuff as you have found out.
The terminals can be dropped out the back of the fusebox holder by using a thin "pick" to unlock the tang on the back of the terminal.
You may have issues with this if it has completely melted.
As a temporary fix you may be able to cut the wires at the back of the fusebox, and crimp on two female blade connectors ( Insulated, and put a new fuse directly in them.

From the look of it a replacement fusebox is required
Post #1045638 12th Sep 2024 2:48pm
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Oldowner



Member Since: 26 Dec 2018
Location: South west
Posts: 612
United Kingdom 2007 Defender 90 Puma 2.4 HT Aintree Green
Replacement 300tdi fuse boxes never used to be available, nor did the specific fuse box connectors. Many years ago I had to repair one, I had a spare complete 300tdi loom and cannibalised it for the fuse box / connectors. This may have changed in recent years.

To get the connector out of the melted fuse box use a soldering iron to push it out, it will heat the connector up and melt the plastic allowing it to release.
Post #1045688 12th Sep 2024 11:31pm
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Roverdrive



Member Since: 11 Aug 2024
Location: Wirral
Posts: 10
United Kingdom 
I have just checked with Alan at Overlandrs and they are “ available but not cheap “!
Might be worth giving him a call 01514767002
Post #1045730 13th Sep 2024 12:25pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20115
United Kingdom 
Maybe Bluesea do one, or very similar? Just an idea NEVER SURRENDER! ⛽️🛢️👨‍🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧
Post #1045731 13th Sep 2024 12:32pm
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anotherrick



Member Since: 02 Feb 2024
Location: Lancashire
Posts: 24
 1997 Defender 110 300 Tdi CSW Rioja Red
Thanks guys. Weather permitting I'm going to investigate it this weekend working my way back from the buld to the fusebox. When using the search I found that there can be an issue with the routing of the loom along the inner wing. Then I'll check the connections in the fusebox and probably make a temp repair until a new one arrives.
Not looking forward to replacing it though.
Post #1045759 13th Sep 2024 7:42pm
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