My 92 244 was not starting. After being towed to the dealer, the RPM sensor was replaced and now the car starts fine. HOWEVER, the dealer mentioned that the fuse box is badly corroded and in need of replacement. I have been looking on the web for a replacement fuse box in an attempt to replace it myself (and hopefully save some of the $500.00 dealer estimates for repair). Is this doable by a DIY? And if so, where can I get a new Fuse Box? Thanks.

I was told the same thing a while back. As has been noted, you probably don't need to replace it. I didn't even remove it, just sanded the contact points with fine grit paper and used the smallest touch of silicone grease on the ends. I opted for the glass fuses and have had no problems.

As has also been noted, be sure to also find the leak. I had water comming in around the hood-pull.

The others who have responded to this thread covered cleaning the fuse holder, I would only add that this is much easier to do if you remove the kick panel first. It's much easier to see what you are doing and easier to clean the connections at the fuses.

Disconnect the battery before using a wire brush on your fuse holder.

I have always replaced the ceramic fuses on 240s with glass Buss fuses but have been having some failure issues with my latest car. The fuses for the fuel pumps and for the air conditioner run so hot that they melt the solder inside the fuse. The fuse never blows, it just stops working. I replaced those three with new ceramic fuses and haven't had any problems since.
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don hodgdon '89 744ti, '81 242t, '71 D-35

I have had the ceramic fuses on the fuel pump melt on me a couple of times in my '80 and '77 though...

That's a lot more of a mess then a unsoldered glass one.

It is possible to clean an old one up, with a small wire brush, some fine emery paper and a helluva lot of patience. Then replace the old fuses with the glass type that dont' corrode. Then, remount the fuse box so that some waterproof sheet of some type sits behind it to protect it, then find and cure the leak that caused the corrosion in the 1st place.
A new fuse box isn't difficult to install. Try your Volvo dealer or IPD if you insist on a new one.
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Still no weapons of mass destruction, except those possessed by Uncle Sam.

I have never seen one that is corroded so much as to need replacement and my guess is that neither has the dealer. Even if it turns out it needs replaced there have to be many available in 240's sitting in the recycling yards.

I would remove all the fuses and use a brass brush to clean all the contacts. You might even consider using a dremel tool with a brass brush to get at those hard to reach areas. A little electrical contact cleaner sprayed on might be a nice touch. I would go to a good auto supply store and get the glass tube type fuses of the correct rating. They will have the pointed ends necessary to fit correctly. Make cleaning the fuse box a scheduled event if you see the corrosion coming back.

Randy

Hello:

I would look for a one out of a wreck that is dry and uncorroded. The first thing you need to do, though, is fix the water leak that caused it to corrode in the first place!

Good luck!
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Herb Goltz, London, Ontario, Canada '92 245 w/97K mi

If he sees this I was wondering if anyone would comment on the leak...

Probably the door hidges leak like sieves... I recently discovered such things on my 85' These ain't leakin no more!~ Mac