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bear924 · Posted: Wed May 17, 2023 9:56 am Post subject: Fuse Box Repair

Recently I decided to find out why my LHS low beam headlight wasn't working. After fault finding, I determined that my issue was the connection between the load size of the fuse and the male pin in the fuse box. (ie. The pin in the fusebox had failed).

On opening up my fuse box I found one of the male pins broken from its base. If I'm able to find a new pin and install in the board, I could repair my fuse box. Having a google I can easily find the connector pin (ie the female pin that resides in the plug that connects to the fuse box) however can't find anything to replace the fuse box pin (ie the male pin mounted in the fuse box).

Has anyone replaced a pin in the fuse box before?

bear924 · Posted: Tue May 30, 2023 7:30 pm Post subject:

So after many hours of looking at pin specifications, today I successfully replaced my faulty fuse box pin. This is the male pin that slides into the female connector located in the plug that plugs into the back of the fuse box.

The pin I replaced was for the LHS low beam (seems to be a common failure point). Specs for the replacement pin I used:

Manufacturer - Mill-Max
Mill-Max p/n - 4639-0-00-80-00-00-08-0

This pin is a little shorter than the OEM pin however has correct diameter.

To repair the fuse box you can lever off the lid. Then remove the necessary layers of busbar (the LH low beam headlight was only second layer down and easy to reach).

I used a 10mm mild steel plate and drilled a 2mm hole in the plate. I used this plate to hold the pin at its collar and then used a hammer to mushroom the top over the busbar the pin needed to connect to. It was relatively easy, just make sure you take lots of photos as a number of the busbars are loose at this fuse box layer.

I noticed I had another pin showing signs of heat (think it's tied to ignition). It hadn't broken so I cleaned it up. If you happen to have your fusebox out (or have an electrical problem) I would at a minimum check the pins and connectors for signs of heat. If you have an electrical issue, it could be that your pin to connector is either too high of a resistance, or possibly broken internally (the OEM male pin are hollow and possibly weakened by the heat).