My low beams cut off after 20-30 minutes. Trusted dealer odbll statedit is getting power to all spots,steering column and relays. When looking at relay in under hood fuse panel, it is the one full forward and inboard relay. It is 5 prong and one prong not getting juice. Could be burndt or loose.(not relay but underside of fuse block)

Question is how to remove fuse block safely to inspect and repair?
If block needs replacement b/c it is burnt, part is $315.00
David

 

The fix is pretty straight forward.


Disconnet the battery, disconnet the postive cable to the fuse block under the hood.

Spin all the center bolt straight down the center of the fuse loose/off, pop the side tabs that are holding the upper fuse block the the lower fuse block, then lift the entire top fuse block asssembly off the base.

Take a quick photo of the fuse block so you know where all the fuse and relays go back in, then pull them all from the upper fuse block section.

Flip the upper fuse block over, and now you need to de-roll crimp the sleeve ferules on the bottom of the block sleeves so you can separate the top cover of the fuse block from the center section.

With just the center section of the block in hand, chase the wire runs to find the wire that is broken and separating from itself when the wire warms up, and install a new wire. Now on top side of the block, install a secondary wire between the same two lugs that you just replaced the first wire on the bottom.

On the top side of the center block where the fuses will snap into those legs, give then a quick check for any that are bent open from heat clean then back up/ bend them back closes.

As for the ferules sleeves that you had to bend open to separate the two parts of the upper fuse block assembly, you can just re roll crimp them to hold the two pieces together, or don't even worry about it, since the bolts down the center of the fuse block will hold them together instead.

 

I saved a thread and made it into a PDF just in case my 2006 has a similar issue before GM can get the recall parts from GM.

Thanks to the original forum member for doing a pictorial of the work required.

 

thanks...I saved it too.

 

What does this all mean below. It sounds like only two pieces, top half and bottom half. Where did the center piece come from? Thanks
David


With just the center section of the block in hand, chase the wire runs to find the wire that is broken and separating from itself when the wire warms up, and install a new wire. Now on top side of the block, install a secondary wire between the same two lugs that you just replaced the first wire on the bottom.

 

As stated above, it's simply one broken wire inside the fuse block. It is literally five cents worth of wire that needs to be replaced. Please don't go spending $300 on a new fuse block. Look through the DIY, the picture of the broken wire is clear.

Here's the thread that the above .PDF was taken from. Member Senseoftouch did a great job with explanation and pics. Lots of reading, his explanation starts on the fifth page of the thread:

https://www.corvetteforum.com/forums...eadlights.html

 

Three pieces to the fuse block assembly.

The bottom section that will stay bolted in the car, the center section that has the wire leads from terminal to terminal, then the top section that is the guard/fuse holder section on top (rolled sleeve furels hold the middle and top section together).


So right hand side is the lower section with wire harness blocks, and in his hand, the middle and top sections


Middle section alone with the fuse holder cap removed from the middle block,



Top cap piece with the fuses/relays still attached (4 pieces if you want to include the fuse block cover)

 

The red circle, is that the break and how to repair that?
David

 

Yes, and go to this below link (page 5, post 85) to see how to not only replace the broken wire with a new wire, but to add a secondary wire on the other side of the block so it does not happen again.

https://www.corvetteforum.com/forums...eadlights.html