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    Thread: Fuse box above battery melting

    1. Member VdubXXIV's Avatar
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      08-13-2010 05:37 PM #1

      On my MKIV Jetta the wire going to S177 is getting super hot an melting my fuse box, an im talking from the time I start my car to pop my hood the fuse box cover will burn your hand. Anyone know why this is happening? I used a voltage meter an it reads 14v but the wire running from the fuse box to the alt gets super hot, an it only gets hot on the side of the fuse box. Could it be a bad alt?

      Help


      Car in need

    2. Member VdubXXIV's Avatar
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      08-13-2010 06:45 PM #2
      Bump

    3. Member VdubXXIV's Avatar
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      08-13-2010 08:16 PM #3
      Nobody really?

    4. Member unclubbedvdub's Avatar
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      08-13-2010 09:14 PM #4
      This is very prone to melting. It's a known issue with our cars. It tends to melt around the three green buss fuses located in the box. When it finally melts you will lose you cooling fans and start to get a weird collage of symptoms. Replace the box when you start to see it melt.

    5. Member denimboy's Avatar
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      08-13-2010 09:15 PM #5
      where did you get your skirts en bumper

    6. Member unclubbedvdub's Avatar
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      08-13-2010 09:17 PM #6
      S177 runs directly to the starter not the alternator btw. I hope this all helps

    7. Member VdubXXIV's Avatar
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      08-13-2010 10:15 PM #7
      I know it's a common problem I'm just asking what's the fix for it?

    8. Member VdubXXIV's Avatar
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      08-13-2010 10:19 PM #8
      Quote Originally Posted by unclubbedvdub View Post
      S177 runs directly to the starter not the alternator btw. I hope this all helps
      I appriciate it.
      I'm also throughing codes now
      Global code*
      PO353 ignition coil c primary/secondary circuit malfunction

      17072 main relay load circuit

      17769 ignition timing cylinder 3 open circuit
      Last edited by VdubXXIV; 08-13-2010 at 10:24 PM.

    9. Member VdubXXIV's Avatar
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      08-13-2010 10:21 PM #9
      Quote Originally Posted by denimboy View Post
      where did you get your skirts en bumper
      the whole kit I got off the dealership.

    10. Member The Sage's Avatar
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      08-13-2010 10:33 PM #10
      I have seen a bad alternater cause this along with alternater cable and even most recently i had a walmart battery cause the wiring to get hot in a car.

      The most recent was a 2004 1.8t jetta had a walmart battery. replaced the fuse panel, battery and power cable to the alt. fixed it.

    11. Member VdubXXIV's Avatar
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      08-13-2010 10:42 PM #11
      Quote Originally Posted by The Sage View Post
      I have seen a bad alternater cause this along with alternater cable and even most recently i had a walmart battery cause the wiring to get hot in a car.

      The most recent was a 2004 1.8t jetta had a walmart battery. replaced the fuse panel, battery and power cable to the alt. fixed it.
      It's just weird that this is happening cause I really havnt drove the car an all of a sudden this happens I did put an upgraded battery in it cause of my pumps. But I can't see that being the problem

    12. Member The Sage's Avatar
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      08-14-2010 01:06 AM #12
      check for high resistance in the alt cable. or all the extra work the alt is having to do because of the extra load on the battery.

    13. Member drumr's Avatar
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      08-14-2010 01:45 AM #13
      just had this happen. i think it happened along with my alternator going dead because i had dead alternator symptoms and the box was found melted when they did the alternator service. my starter was doing the squealing that all VWs do and they replaced that while they were in there. said it also could have had something to do with my sub-woofer but it's only a 760w and it doesn't stress the power system at all... the lights dim more from rolling the windows up and down and not at all from the amp.

    14. Member juancameijeiras's Avatar
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      08-14-2010 04:58 AM #14
      fans resistors are gone, either replace the fans (expensive) and the problem will come again in few years or get an alternative to run the fans at low speed (digital controller)

    15. Member Evenodds20's Avatar
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      08-14-2010 05:20 AM #15
      This is definately the alternator wire. I have replaced 2 boxes before i figured out what it was. I sloke with a vw tech and he explained to me that over the years the wire begins to build resistance and that means higher temps. 177 in that diagram goes directly to the alternator. Not the starter. Replace the alternator wire with any 2 gauge battery wire from advanced auto. I used a 4' negative cable so it would be the same color as the original. Ive been melt free for over a year now.
      Wombats

    16. 08-14-2010 11:24 AM #16
      Quote Originally Posted by unclubbedvdub View Post
      S177 runs directly to the starter not the alternator btw.
      Umm, NO, there is no fuse for the starter - it is wired directly to the battery.

    17. Member VdubXXIV's Avatar
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      08-14-2010 11:54 AM #17
      Thanks guys I appreciate all the input

    18. Member Evenodds20's Avatar
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      08-14-2010 05:01 PM #18
      like i said, the 177 runs fron the fuse box, under the battery, through a black clamp that holds a few different wires, and it continues under the intake manifold to a bolt on the side of the alternator. change that alternator wire. it has alot of resistance and is getting extremely hot. the box costs about $100. if you dont replace that wire that only cost $10 with it, you run the risk of melting that box AGAIN (like i did) and having to buy yet another box. do yourself a favor and take it from someone that has had this issue first hand.
      Wombats

    19. Member swagger rob's Avatar
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      08-14-2010 05:26 PM #19
      I feel like there should be a recall on these

    20. Member swagger rob's Avatar
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      08-14-2010 08:49 PM #20
      Meh.

    21. 11-10-2010 10:19 AM #21
      I recently had this same issue-- A couple days before my car quit, the check engine light went on. I ignored it thinking it was probably the O2 sensor... two days after, the abs and airbag lights came on and 10 mins after that my car lost power.

      I was able to coast my car right to a sears auto store parking lot (sunday night...)... and being that I do not have a ton of experience I felt pretty lucky! No need to tow.

      They said it was my battery (wrong), charged me $120, and sent me on my way. Later that day car quit again, this time 2hrs from home. I ended up at a nice little shop that helped me learn more about what was happening w/ my car- they found that it wasn't the battery, and the alternator was running fine... so I found this thread, which helped us fix my car.

      Thank you! I changed the cord and used a negative to keep it the same color. We rigged it so it works, but it's connected directly to the battery w/o a fuse. Which I KNOW is not good, but it's running. I am looking for a new junction/fuse box and am wondering this... does it matter what year the part is from? I have a 2004 Jetta wagon 2.0.... and I'm thinking they have to be the same from certain years... any input?

      Before:

      After!!!:

    22. Member Skinner's Avatar
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      11-10-2010 10:23 AM #22
      Quote Originally Posted by swagger rob View Post
      I feel like there should be a recall on these

      prob the entire MKIV platform in general
      SixDigitClub
      (FiSHBOWLSTAtUS) ><(((*>
      Suede is Played
      ♥ Mila

    23. Member linchpin.666's Avatar
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      11-10-2010 10:36 AM #23
      Quote Originally Posted by Evenodds20 View Post
      the box costs about $100.
      I got one off of ebay for $25

    24. Member linchpin.666's Avatar
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      11-10-2010 10:38 AM #24
      Quote Originally Posted by kbontia View Post
      I am looking for a new junction/fuse box and am wondering this... does it matter what year the part is from? I have a 2004 Jetta wagon 2.0.... and I'm thinking they have to be the same from certain years... any input?

      According to ECS, there are different ones for different years. You can get a brand new one for about 90 bucks, or you can get a used one from ebay for a lot cheaper.

    25. Member Bazmcc's Avatar
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      11-10-2010 10:39 AM #25
      Faulty alternator loom. Just replace it.

    26. 11-11-2010 12:06 AM #26
      Quote Originally Posted by Bazmcc View Post
      Faulty alternator loom. Just replace it.
      so you think the alternator is going to go next? So I should just replace it?

    27. Member Bazmcc's Avatar
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      11-11-2010 04:07 AM #27
      Quote Originally Posted by kbontia View Post
      so you think the alternator is going to go next? So I should just replace it?
      Nope.

    28. 05-16-2012 10:27 PM #28
      I had the same problem with my 2004 Jetta. The first fuse kept melting. We would replace it and it would happen again. We finally took it in to the dealership and they said they alternator harness was giving off too much power so they replaced it and we haven't had any problems since.

    29. Member edggar's Avatar
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      05-16-2012 11:08 PM #29
      i had the same problem too, went to a audio shop and got some nice 2 gauge wire and replaced the the wire coming from the alternator to the battery.
      The dealer wanted 100+ dollars for the original wire, I spend 20-25 on 12ft of a really nice stinger wire.

      It took me a few hours, but my custom wire is better than the original wire.

    30. Member naitsyrkk's Avatar
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      06-22-2012 06:47 PM #30
      this just happened to me today ever since it got really hot the other day my cars been dying couldnt figure it till i opened the fuse box and that first black wire was melted with all the plastic around it. i think its just in the 2004 cars mines an 04 R

    31. 06-23-2012 02:10 PM #31
      so that black wire is $10?? Is that called the alternator harness?

    32. 06-23-2012 02:12 PM #32
      Quote Originally Posted by Evenodds20 View Post
      like i said, the 177 runs fron the fuse box, under the battery, through a black clamp that holds a few different wires, and it continues under the intake manifold to a bolt on the side of the alternator. change that alternator wire. it has alot of resistance and is getting extremely hot. the box costs about $100. if you dont replace that wire that only cost $10 with it, you run the risk of melting that box AGAIN (like i did) and having to buy yet another box. do yourself a favor and take it from someone that has had this issue first hand.
      So that black wire costs $10 and can be replaced separately without buying a new box? is that black wire the alternator harness? because i priced alternator harnesses at $100+...
      Last edited by Shara; 06-23-2012 at 02:14 PM.

    33. 06-23-2012 02:16 PM #33
      Quote Originally Posted by naitsyrkk View Post
      this just happened to me today ever since it got really hot the other day my cars been dying couldnt figure it till i opened the fuse box and that first black wire was melted with all the plastic around it. i think its just in the 2004 cars mines an 04 R
      no, I have a 2003 and i'm having the same problem...

    34. 06-23-2012 02:25 PM #34
      Quote Originally Posted by naitsyrkk View Post
      this just happened to me today ever since it got really hot the other day my cars been dying couldnt figure it till i opened the fuse box and that first black wire was melted with all the plastic around it. i think its just in the 2004 cars mines an 04 R

      what are you going to do to repair it?

    35. Member naitsyrkk's Avatar
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      06-23-2012 03:54 PM #35
      im just gonna get a regular 2 guage wire from advanced and a new power distribution box since mine is all melted. completly off topic but good news is one of my rotiforms came in hah still gotta wait for the other three firgured id share that

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