QuestionI have a 2001 corolla. The main fuse blew about three months ago. I had the dealer replace it. They did some kind of electrical check and found nothing wrong. The car has been running fine.
I smelled a burning smell yesterday. The car would start but would not go into gear and no dash lights. I wiggled the main fuse and they worked again.
I took the fuse box apart and the main fuse (100 Amp) wire was lose and the wires were melted and burned. The fuse never blew but the box and wires are trashed.
What do you think caused this problem?
Do you think that the guy just didn't tighten the fuse?
Seems unlikely to be that incompetent?
How can I trace the short?
Should I just replace the fuse box and see if the fuse blows again.
AnswerThe fuse boxes are not generally opened, or removed to inspect the wiring. I would guess the wiring was installed incorrectly into the terminals originally, and they've finally become loose enough to short out. If the fuse itself wasn't pushed down, or clamped into place. It would simply melt as-normal.
I would replace the entire fuse box, including the components inside it(don't re-use them without testing them). The problem with the box now is that it's problem is only going to get worse.
Tracing a short can be very difficult without running across it. One would assume the fuse box is the entire problem, but there is no way to be sure without being there in-person. I would concentrate efforts in the main power, and grounding wires for the fuse box.
I would likely check a salvage yard (ebay) for a used unit, and test it's components before installation. www.TAPRecycling.net is a Toyota/Lexus/Scion only salvage yard located in California. At times Toyota parts can be hard to find.
You could also just go to a Toyota/Lexus/Scion dealer & have it replaced.
