Fusebox repair/restoration

[eddbmxdude]

Hello everyone,

I've got a Toyota Townace and it's been one headache after another. I bought it in February and between then and now, it's been out once.

The latest saga is the fusebox. I've had in in my workshop to sort an oil leak and somehow all the wiring under the dash is wet. I suspect it's condensation because I've drained all the coolant from the system and it's inside, although it's not a very well sealed building. It's strange because I've had countless vehicles stored in there for the last 12 years and never had a problem with condensation.

Anyway, it's happened and as a result the fusebox has gone manky. The terminals have started to go crusty and the fuses are all loose in their slots. I'm having problems starting it and I want to rule out dodgy connections. Is there any way to repair a fusebox where all the fuses have gone loose?









The white dust is fire extinguisher powder from a fire caused by an aftermarket alarm which is long gone now. I've had the dash completely out and cleaned behind it but the powder is still appearing Would the powder react with the metallic connectors and accelerate corrosion?

I really don't want to buy a replacement (If I could find one). Parts for this thing are rare and expensive and I've spent a fortune on this thing already.

Here's a photo from the one time it made it out of the workshop, mainly to help with my own motivation






Any help/advice massively appreciated.

Thanks,
Edd

[comfortablynumb]

IIRC some fire extinguisher powder is corrosive in this way, i think you might be p£&@/ng in the wind trying to repair the original, is it possible to use a fusebox from something else, or maybe one of the J grey importers might be able to help with a replacement?

[Ritchie]

It doesn't look overly complicated. I'd have a look at Car builder Solutions and see if they have a universal one which could be used.
It would be better to replace, it doesn't look like you could ever trust that one to be reliable.

[kevins]

If you can get it apart they are usually just strips of brass formed to hold the fuses, clean them up (immerse in vinegar works), rinse with distilled water, dry out then squeeze the connections a little tighter and put it all back together.

[eddbmxdude]

Thanks all.
Kevin, I think I'm going to give that a go. I've got nothing to lose really. Will report back.

[eddbmxdude]

So, I drilled out the plastic pegs on each corner of the box. The housing is held with clips around the edge too, so when I reassemble it I can just clip it back together. I guess the pegs are a belt and braces approach.



Carefully prized it open.



I little intimidating at first. A lot of crust and some parts fall out.



But on closer inspection the only things actually broken are three fuse holder terminals. That explains why the fuses have been falling out and probably also why my glow plug circuit has mysteriously stopped working.



I just need to find some of these connectors. The only number on them is B2. It's got a standard female blade terminal on one end and a female socket on the other with a tang to hold the fuses tight. I've tried Googling crimp connectors, spade connectors, spade adaptor terminals and a few other things with no luck. It doesn't look propriety but I suppose it could be. Anyone know what they might be?










A connector with a female blade terminal on both ends would probably work too, as long as it was the same height.

Edd

[privatepile]

Try Kojaycat for the terminals

[eddbmxdude]

Oct 10, 2019 10:47:56 GMT privatepile said:

Try Kojaycat for the terminals

Thanks. Had a look on there and RS, Farnell, Ebay and a variety of other places with no joy. It doesn't help that I'm not even sure what they're called.
The other option is to buy a Toyota fusebox from the same era and use it for parts.

I bathed the fusebox in vinegar last night and then dunked it in a stop bath of water & bicarbonate of soda. Any recommended products for protecting the contacts from corroding again? I was thinking of giving it a squirt with WD-40 before I reassemble it.







Cheers,
Edd

[chamba]

Bikers swear by using an anti-corrosion spray called ACF50 on contacts and the like.

[Ritchie]

Oct 11, 2019 22:04:44 GMT chamba said:

Bikers swear by using an anti-corrosion spray called ACF50 on contacts and the like.

Yep, I'd back that up. I've used it and it's good stuff.

It was originally designed to protect aluminium on aircraft.