Hi, the positive supply to the under bonnet fuse box is tight, no sign of any corrosion etc. I did notice though that the 2 fan relays were very warm. I prised the yellow cover off one, the coil winding was hot to the touch. I've swapped them with the screen heater pair to see if they run cooler. May be a complete red herring! Thanks for all the help so far.
 
Hi, the positive supply to the under bonnet fuse box is tight, no sign of any corrosion etc. I did notice though that the 2 fan relays were very warm. I prised the yellow cover off one, the coil winding was hot to the touch. I've swapped them with the screen heater pair to see if they run cooler. May be a complete red herring! Thanks for all the help so far.

Any sign of blueing on the contacts where they plug in? If so it's likely your fuse box is knackered, a common fault. Check the ignition relay as well.
 
Hi Datatek, no sign of any heat damage to the contacts but it does smell like theres a circuit board overheating in the fuse box. Is there anything I can check before buying a new one. I expect they don't come cheap! Thanks again for your help.
 
Hi Datatek, no sign of any heat damage to the contacts but it does smell like theres a circuit board overheating in the fuse box. Is there anything I can check before buying a new one. I expect they don't come cheap! Thanks again for your help.

If it smells of burning it's knackered. Common problem I'm afraid:) If and when you replace it, make sure that there is no sign of heating/burning on the connectors underneath. If there is, you may need to clean and tighten individual connectors.
 
Thanks Datatek, I've just ordered a replacement. Hopefully it'll arrive before the weekend. I'll let you know what I find when I remove the old one.
 
It's a second hand unit, if it turns out to be faulty too at least I get a full set of relays and fuses ! I'll let you know how I get on.
 
The replacement fuse box has arrived, just realised the diesel and petrol versions have different serial numbers. So my question is what is the difference? Can I use the petrol version in my diesel P38? Connectors underneath look the same, only difference seems to be one of the 'Maxi' fuses. Thanks.
 
The replacement fuse box has arrived, just realised the diesel and petrol versions have different serial numbers. So my question is what is the difference? Can I use the petrol version in my diesel P38? Connectors underneath look the same, only difference seems to be one of the 'Maxi' fuses. Thanks.

There are several different fuse boxes, I think you need the correct one but I'm not sure an compatablity.
 
Hi all, I've found the cause of the problem in the old fuse box now, the positive feed post had broken away from the circuit board and must have been arcing to get a circuit most of the time. As the second hand fuse box I bought doesn't seem to be the right one I've ordered a new one (part no AMR6477). Hopefully it'll arrive tomorrow and I can get back to business. Thanks all for your help. If anyone needs a 4.6 2001 fuse box in very good condition please let me know.
 
Hi all, I've found the cause of the problem in the old fuse box now, the positive feed post had broken away from the circuit board and must have been arcing to get a circuit most of the time. As the second hand fuse box I bought doesn't seem to be the right one I've ordered a new one (part no AMR6477). Hopefully it'll arrive tomorrow and I can get back to business. Thanks all for your help. If anyone needs a 4.6 2001 fuse box in very good condition please let me know.

Glad for you , could you put it in the for sale section , better in their than here for you and others :)
 

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