HOW TO: Replace your XJ fuse block for $5

There are much better fuse blocks out there (ie. ATC style), but I found this block cheap and it's working great!! This one is a little more exposed to the elements than the old one too. It took me less than an hour from start to finish.

I purchased the 4 post glass style at O'Riley Auto Parts, but this Buss part might be available at several parts stores.

The fuse block was $1.99 (Buss part number BP/S-8202-4) and the electrical connectors were $1.99.


First write down wire colors and amp specs (20a main, 10a other three), then take off all the connectors from the old fuse block. Several of the old fuse holders were broken and were giving me intermittent signals and headlight.

Cut off the old fuse holders and crimp on the new connectors.

Trim off all the plastic holders on the bottom of the old block so the new one will fit flush on the bottom.

Zip tie the new block to fit inside the old block (see picture below). This made a very snug connection, and it should not move around at all.

Assemble the connectors and install the fuses.

Trim the old fuse block cap so the connectors can fit around it (see picture below)

I used a velcro strap to hold the cover in place so it could be removed easily.

With the wires sticking out of the block, you should be careful each time you put on the seat so you do not pull a wire out of the fuse block.

 

More pictures.

 

Pretty sweet. One question: how come you didn't got with the more modern fuse style? Is there any advantage to staying with Glass? I'm going to perform the same operation, but was planning on using the new bladed fuses.

 

well thats tough to beat for the price... i was going to try to go with no glass fuses but for 1.99 if i can find one around here... i'm going this way. thanks for the info and Pics!!

 

bah no luck finding one around richmond Va... haha i wonder if that store you went to ships

mmm on second thought i bet i can order one online... off to search around, If i find a place, i'll post a link.

 

Nice Job

 

I went with this model mainly because I couldn't find an blade type anywhere local. I wanted to get it fixed ASAP since I drive it daily to work.

When you're looking for the block, it was located by the rack of fuses, NOT behind the counter.

BTW, I noticed all my signals were MUCH brighter after installing the new fuse block.