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Melted Plastic On Fuse Box Terminal Connectors


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#1 nospamprl

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Posted 30 October 2012 - 05:05 AM

Last time I drove at night I perceived a burned plastic smell around the fusebox, close to my spotlight relay. I arrived home after a few minutes and everything was working fine.

Last night I was driving on a dark road, and when I turned on my main beam, all lights went off. I first thought about a blown fuse, but that was not the case.

After checking the (4-fuse) fusebox, I noticed there were 2 wires entering the fusebox for the 2nd (top to down) fuse. Both wires had their plastic insulation melted and they were not making proper contact. I removed them and replace the terminals with new ones and everything is back to normal again.

I haven't had the opportunity to drive again for a long time with the lights turned on. I wonder why those connectors can get so hot and don't know if it is a problem that has been developing during the years or if something may be suddenly wrong in the wiring. I would appreciate your help.

I have the standard headlights, plus 2 fog and 2 spotlights (wipacs). But yesterday everything went off immediatly when turning the spots on, the only ones being on before everything shut off was the 2 standard headlights.

Thanks

#2 Yoda

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Posted 30 October 2012 - 06:01 AM

I assume you mean the two brown wires at the fuse box?

If so, you have probably got corroded connections here causing a high resistance therefore heat, Also i suspect you have spotlights connected directly to the headlamp wiring and not through relays. Bad practise. they should be fused independantly and fed through relays to prevent exactly this problem you have.




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