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1995-2002 Range Rover P38A
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Discussion Starter #1
Ok. So I gather that the plastic used to make the PCB boards on my fuse box after 15 years of hot and cold causes minor cracks in the circuits on the board. After many years of this the arcing that the voltage does to jump these cracks puts strain and extra load on the relays. The relays in turn run hotter and the excess heat causes them to cook the plastic of the relay turning the outer shell brown. If left uncared for this process will continue until the actual plastic under the relay starts to melt. After melting the relays stop working and the electrical current continues and eventually a fuse box fire starts. Much like the Jan 1st fire in a Carpark in Liverpool which claimed lots of cars... upwards of 10 million pound I read.... so. For those with more experience.... do I just replace the fuse box and relays for brand new and expect to get another 15 years out of the new hardware? I’ve got several browning relays and my SAI Pump has run twice after I turned the car off and took the keys out. RL 10 didn’t smell weird or seem bad but it was definitely stuck open at one point. LR direct has a box and all new relays for $228 delivered. Can I use the same old fuses? I don’t want to start a fire and burn my house down. So.... is my logic correct in identifying how a fuse box dies?
 

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1995-2002 Range Rover P38A
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Well- apart from using the example of the Liverpool fire, which wasn't a P38 and the cause of ignition is still unknown, but we'll move on from that...
Have you read through the "fuse box repairs" guidance?
In short, just replace with a new OEM item. They come with fuses and I believe Atlantic British will even sell you a new relay set to suit.
http://www.island-4x4.co.uk/fuse-petrol-9902-genuine-yqe103410-p-7047.html if you want to import one
http://www.roverparts.com/Parts/YQE103410G if you don't
and the relay kit
http://www.roverparts.com/Parts/YQE103410RELKIT
Do it properly and even if you have to do it again in another 15 years, it's not that big a deal.
 

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I think you have the right idea. I just consider the fuse box assembly as one of the expandable components, expected to be replaced every couple of years.

The old relays, even if slightly browned, usually work pretty well. I would caution against getting cheap no brand relays. Outer shell deformed right away from my experience, and I had to reuse the old browned relays, which coincidentally, worked well.
 

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Discussion Starter #5
THAnks for all the info. I sourced the box and relays from LR Direct. Hope to tackle that in a few weeks.
 
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