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#1
06-28-2016, 09:00 PM
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Fuse body melts but not fuse
So I am having an interesting problem on my 190E. The fuse for the aux fans has gotten hot enough to melt the plastic body of the fuse but not the fuse itself. This seems abnormal but the system is working fine otherwise. I have the fans running full time but the melting was also happening when I wasn't running them full time.
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Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon. 
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#2
06-28-2016, 09:03 PM
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You have a "hot" connection in the fuse holder. Disconnect the battery and use some very fine sandpaper to clean the points that the fuse clips into. Rub some dielectric grease on both ends of the new fuse and see if that helps out.
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Current stable: 1995 E320 149K (Nancy) 1983 500SL 120K (SLoL) Black Sheep: 1985 524TD 167K (TotalDumpster™) Gone but not forgotten: 1986 300SDL (RIP) 1991 350SD 1991 560SEL 1990 560SEL 1986 500SEL Euro (Rusted to nothing at 47K!)
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#3
06-28-2016, 09:18 PM
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Nope... It's a common issue with these cars... First, make sure you have CERAMIC fuse bodies... Copper, or tinned copper... NOT ALUMINUM!!!
Second, take the motor out, and clean the bearings. As the bearings wear or dry out, the motor pulls more current but not enou to blow the fuse...
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!!  1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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#4
06-28-2016, 09:24 PM
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Forgot to mention the copper/ceramic fuses.
Still check the fuse holder. A hot connection will melt the fuse body without popping the fusible link itself. If you have a crusty or corroded fuse holder, it doesn't matter what fuse you put in there, you'll eventually wind up with a melted fuse box, a melted fusible link, or a fire instead, whichever is the first to fail.
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Current stable: 1995 E320 149K (Nancy) 1983 500SL 120K (SLoL) Black Sheep: 1985 524TD 167K (TotalDumpster™) Gone but not forgotten: 1986 300SDL (RIP) 1991 350SD 1991 560SEL 1990 560SEL 1986 500SEL Euro (Rusted to nothing at 47K!)
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#5
06-28-2016, 09:42 PM
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Quote:
+1 on ceramic fuses, the plastic stuff is garbage. You actually have many fuses in the fan circuit, it would help to know which one was blowing. Read off the label on the cover of the electrical center. The low speed fan relay has two fuses in the electrical center...one for the coil and one for the contacts. If you've never done so, it's a good idea to replace the relay as the contacts develop high resistance over time. The relay itself is usually located in the electrical center. The high speed relay has one fuse in the electrical center for the coil, and a fuse internal to the relay for the contacts. If you still have the original black relay, you should discard it. The current replacement is either green (30A) or orange (40A) and with a separate fuse in the top, depending on whether you have one or two fans. The high speed relay is usually in a black plastic box just forward of the electrical center. Once the fuses and relays are squared away, you want to remove the fan and disassemble, clean the bearings and lube with one small drop of synthetic oil in each bearing. To get the fan blade off, bend up the locking tab and turn the nut clockwise...the thread is reversed. Finally, remove the connectors on the resistor and clean the contact tabs.
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