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Author Topic: Additional fuse box wiring.  (Read 1173 times)

Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
Additional fuse box wiring.
« on: January 29, 2018, 05:14:39 PM »
I have replaced the additional fuse box with a new one and also the 150 amp loom to the alternator but the 110 amp wire is still getting hot. Its part of the main loom any suggestions?

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Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #1 on: January 29, 2018, 05:17:00 PM »
Here's a picture

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Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 3024
  • Thanked: 112
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #2 on: January 29, 2018, 05:47:17 PM »
Have you soldered a new terminal to the cable?
I would advise the new alternator cable is also soldered this will prevent any further issues
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #3 on: January 29, 2018, 08:04:55 PM »
Hello Chris you reckon if i cut the terminal off solder on a new suitable terminal on that will be good enough. I'm thinking there's just contact resistance in that end .

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Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #4 on: January 29, 2018, 08:05:49 PM »
Chip the ring off and solder a new one on,that’s what I did with mine I also swapped it with the wire at bottom so it was further from alt one. Don’t forget to swap the side position over aswell.

As above also run solder in to the alt wire/ring to prevent moisture ingress in future.

Offline Chrispb

  • Mindsaysyesbodysaysnono
  • *
  • Posts: 3024
  • Thanked: 112
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #5 on: January 29, 2018, 10:33:03 PM »
Hello Chris you reckon if i cut the terminal off solder on a new suitable terminal on that will be good enough. I'm thinking there's just contact resistance in that end .

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Exactly that, it's the high resistance that causes the heat, you could end up with another melted fuse box if left.
Personally I feel all high current crimp connections should be soldered that are exposed to the weather.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #6 on: January 29, 2018, 10:45:12 PM »
Thank you for the advice fella's. I will be back on it in the morning.  There's quite a few 16 mm2 110 amp terminal choices on Ebay. Think i might cut the ring off tomorrow and solder an m6 washer for a temporary measure.  Don't want to ruin the new fuse box.

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Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #7 on: January 29, 2018, 11:25:50 PM »
Don’t think you would get decent solder with m6 washer,go down halfrauds if you want quick solution they have ring crimps on the shelf you can use. I did my 110 amp one with those,crimped to cable them heated up with blow torch to flow solder in to it.
Wrapped with insulation tape and protected exposed area with petroleum jelly. Been sweet as a nut for 2 years now. 150amp top of box 110 amp bottom of box to separate the high load cables.

Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #8 on: January 30, 2018, 12:47:45 PM »
All fixed. In the end i used a new crimp connector a new washer and nut and used the red wiring from the old fuse box. Then i cut up a positive battery terminal and used the metal tube as a connector.  Heat shrinked the lot. Its nice and cool now even after a run with lights on blower motor on max, heated seats and heated window on.

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Offline Chrispb

  • Mindsaysyesbodysaysnono
  • *
  • Posts: 3024
  • Thanked: 112
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Additional fuse box wiring.
« Reply #9 on: January 30, 2018, 05:32:19 PM »
 [GJ]
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

 

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