Dodgy electrics

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Speedy88
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Dodgy electrics

Post by Speedy88 » 02 May 2010 11:23 pm

Yo homies, I was out tonight and the car died on me whilst driving along. Seeing as I have had the car clicking the starter (rapidly flashing the electrics and starter at about 10 times a second making the starter click rapidly) over the last few days, I suspected an electrical problem. But I was stumped - I had interior lights and hazards but nothing else! Nowt, no headlights, dash lights, nothing. Stumped and after 20 minutes of poking, I got RAC out. Our man found the problem, the ignition switch wasn't getting main power feed. Feeling the wire to the back of the fuse box suddenly I hear the puel pump and radio kick in. It's alive!!! Worked fine after that although we never did find the exact place where the connection issue was (somewhere behind the fusebox).

So, before I go and have a clean around there tomorrow, is there anything is should be looking out for? I'm aware 300s have a problem with water leaking through there, what should I be seeing?
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Speedy88
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Re: Dodgy electrics

Post by Speedy88 » 03 May 2010 05:47 pm

Well that'd be the problem then, where can I pick up a replacement for this? I'm pants when it comes to electrics and usually make a shoddy crimp job with molegrips.

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'85 360 GLS - Drift project (Sold)
'77 Colt Sigma
'96 940 Drift project

macplaxton
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Re: Dodgy electrics

Post by macplaxton » 03 May 2010 06:02 pm

You should be able to remove that individual terminal and slot in a new one to the block. Somewhere like Vehicle Wiring Products

Solder things - I'll be over to boot your arse if I see one of Satan's Scotchloks on there! sm68
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Chris_C
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Re: Dodgy electrics

Post by Chris_C » 03 May 2010 06:23 pm

Mark, I'm getting the kit to replace these pretty soon (once I've worked out which shape of removey tool get's the crimp out of the plastic) Mines got hot in exactly the same place it's very common and pretty much the only cause of electrical probs on a 300.

It's not helped that the fuse box terminals are brass and the crimps are plated as standard :evil:
'89(G) 340 GLE B172k
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Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

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volvodspec
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Re: Dodgy electrics

Post by volvodspec » 03 May 2010 06:39 pm

i have that tool for the round ones right here at my desk,

it is part no 9996351 "removing tool"

perhaps these wouldn't have been a problem if they didn't use 4mm² wire (but 2x 2,5² in seperate connectors) and didn't tigh the bundeled cables up that close to the connector, there is a lot of tension on it imo

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Speedy88
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Re: Dodgy electrics

Post by Speedy88 » 03 May 2010 07:46 pm

Chris_C wrote:Mark, I'm getting the kit to replace these pretty soon (once I've worked out which shape of removey tool get's the crimp out of the plastic) Mines got hot in exactly the same place it's very common and pretty much the only cause of electrical probs on a 300.

It's not helped that the fuse box terminals are brass and the crimps are plated as standard :evil:
Really are a pain in the arse, such a flimsy system. Was this a Daf or a Volvo unit? Fancy a tinkering session then sometime in the future? Get er done.
'88 340 Williams (Sold)
'85 360 GLS - Drift project (Sold)
'77 Colt Sigma
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Chris_C
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Re: Dodgy electrics

Post by Chris_C » 03 May 2010 08:54 pm

volvodspec wrote:i have that tool for the round ones right here at my desk,

it is part no 9996351 "removing tool"

perhaps these wouldn't have been a problem if they didn't use 4mm² wire (but 2x 2,5² in seperate connectors) and didn't tigh the bundeled cables up that close to the connector, there is a lot of tension on it imo
I agree there is too much tension too.

Do you have the spade tool as well mate? If so I'll head down to Volvo and pick up both if they still exist, else could you take a piccy with some rough dimensions for me?
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

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Re: Dodgy electrics

Post by macplaxton » 03 May 2010 10:20 pm

9996351 looks NLA, it's not on the SPX tools list.
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volvodspec
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Re: Dodgy electrics

Post by volvodspec » 03 May 2010 10:43 pm

actually i'm lucky that at my work the Terberg Trucks use Volvo cabins, thats why i have all that stuff lying around :lol:

there are 3 different tools for the electric connectors around the 300 series fusebox, and i have all 3 of them. the one mentioned above, i don't know if that will be available anymore but the 2 others definatly are, i'll sort some dimensions/part n.o. out soon

the thing you need for those rounded connectors is really simple though, just a hollow pipe made to custom dimensions on a lathe

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Chris_C
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Re: Dodgy electrics

Post by Chris_C » 03 May 2010 10:53 pm

volvodspec wrote: just a hollow pipe made to custom dimensions on a lathe
This I can do :D Awesome news, cheers gents.
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

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volvodspec
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Re: Dodgy electrics

Post by volvodspec » 03 May 2010 11:01 pm

ø5mm outer diameter; ø4,5mm inner diameter; that's all, the tool itself has a spring to press the connector out but with a pipe you can just pull the wire itself, no big deal:
P1000964 (Medium).JPG

note; these connectors still have a volvo part number!!, volvo still uses them for certain connectors

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Chris_C
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Re: Dodgy electrics

Post by Chris_C » 17 May 2010 01:05 pm

Update...

Dealers certainly can't get hold of the tool, but making one now I have Anjo's specs is really easy.

Anjo, do you have said part number for a bag of crimps bud? All the usual suspects (WVP, Simtek, Autospark, PoleVault) don't seem to list them.
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

Ride_on
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Re: Dodgy electrics

Post by Ride_on » 18 May 2010 02:15 am

I had that problem, think it was the 89 360 GLE. I changed the fuse box and soldered in a new pig tail (a connector on a bit of wire) from a donor.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
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Re: Dodgy electrics

Post by Chris_C » 18 May 2010 04:08 pm

Yeah, I was tempted too but I don't like soldering pigtails because of fatigue, plus I'm lucky enough to have the proper crimpy tool.

Plugs are NLA from Mr V, but they do have the 3.5mm bullets with latch to fit the plugs @ 60p ea :o expensive, but at the mo I havn't found another supplier so I grabbed an armful. Part number is on a "post it" in the car, VADIS number is still valid though and I'll try to remember to pick it up later.

I'll start stock piling all the good plugs I see and assembling something resembling a "loom repair kit" that I can chuck in a box and bring to meets or something. As yet I havn't found a new supplier of the housing itself but will see what I can do. I have found a load of Triumph bits that my mate have been looking for in the process so not all bad :lol:
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

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volvodspec
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Re: Dodgy electrics

Post by volvodspec » 18 May 2010 05:55 pm

i believe that they are from AMP, problem is that i can only look up the Terberg partnumber, the original Volvo number it corresponds to isn't listed anymore..

i could look up the other 2 tools this week if i get the chance, those are definatly commonly available as i recently got one of them new from Stahlwille; we use those for a wide variety of connectors, kinda universal tool

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