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100 Amp Fuse Replacement

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by erkoines414, Nov 2, 2006.

  1. erkoines414

    erkoines414 New Member

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    Hey all,

    New Prius owner, old DYI guy.

    Wife got a 2001 Prius. The 100 amp fuse on the drivers side fuse box is blown. How do I get the bugger out? Looking at the new one, it looks like the blades are bolted in.

    I have spent a couple hours trying to get the fuse block apart, but can't seem to find whatever the easy trick is.

    HELP!

    ETS
     
    #1 erkoines414, Nov 2, 2006
  2. naterprius

    naterprius Senior Member

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    That's bad. That's not a fuse, it's a fusible link. They have a slow burn, indicating not just a quick spike in current, but a sustained (too high) current draw. You should locate the short before you replace the fusible link; it will blow again.

    Nate
     
    #2 naterprius, Nov 2, 2006
  3. erkoines414

    erkoines414 New Member

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    <div class='quotetop'>QUOTE(naterprius @ Nov 2 2006, 11:08 PM) [snapback]342983[/snapback]</div>


    I know what blew it. I put the battery charger on the aux. battery without disconnecting the ground. Won't do that again.

    ETS
     
    #3 erkoines414, Nov 2, 2006
  4. tochatihu

    tochatihu Senior Member

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    Hi ETS, I read one account of replacing this fuse in the yahoo toyota prius technical group, and will try to dig that up. But basically you need to unbolt that entire fuse/relay box and lift it up to be able to unbolt the big fuse from below. Obviously everything must be powered down while you are shortin' all those wires together on the underside of the box.

    Rated as "possible but I'd hate to" on the DIY scale. Good luck.

    Previous blowouts resulted from reversed polarity on external 12 volt connections IIRC.
     
    #4 tochatihu, Nov 3, 2006
  5. erkoines414

    erkoines414 New Member

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    <div class='quotetop'>QUOTE(tochatihu @ Nov 3 2006, 10:21 AM) [snapback]343152[/snapback]</div>

    Yeah, that's what I've been working on. Definately a PITA. Not a lot of room in there, especially with the high side A/C line running over the top of the box.

    ETS
     
    #5 erkoines414, Nov 3, 2006
  6. erkoines414

    erkoines414 New Member

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    Alright. It's done, so I'll let you all know how much fun it was. Again, this is a 2001 Base model.

    1. Disconnect the positive lead for the auxilliary battery.

    2. Remove the funnel attachment for the wiper fluid reservoir.

    3. Disconnect the 5 electrical connecters (each is unique so no worries when re-assembling) to the left of the fuse box. Pull that bundle back and undo the tie to the fusebox and the first two ties on the aquarium cover.

    4. Remove at least 1 screw from the bracket holding the bundle connectors that run under the electric motor housing cover. You probably can't get to the second one anyway. I couldn't. Push the bracket down and to the left as much as possible.

    5. Remove the 2 x 10MM bolts that secure the fusebox to the body. I needed a wobbly bar and a 90 degree adapter for the rear one.

    6. Unclip the highside A/C line from the front ground cable and aquarium cover and move it to the left a couple inches. Take care not to kink the line. That would be bad.

    7. Using a flathead screwdriver, unclip the 4 clips (1 on each side) that hold the bottom cover of the fusebox to the top and wiggle the bottom out from underneath. There is a cutout so that it goes around the bundles running into the box.

    8. Use a flathead screwdriver to push in the two clips that hold the fusible link connector block to the fusebox. Slide it out the bottom of the fusebox. Move the main fusebox as far forward as possible.

    9. Disconnect the black connector on the bottom of the link block.

    10. Pry back the 4 arrowhead shaped retainer clips on the longer sides of the fusible link block. Slide the lighter colored covers down, revealing the retaining bolts (4 total) for the link and cables.

    11. Loosen the 10MM bolt holding the link on the right side. Loosen the 8MM bolt holding the link on the left side. Pull out the blown 100A link. You do not need to remove the other 2 bolts.

    12. Replacement is reverse of removal.

    13. Check the rest of your fuses. I had 4 blown 10A and 15A fuses from the original overload. All minor stuff, but blown is blown.

    It's running fine now.

    Happy motoring,

    ETS
     
    #6 erkoines414, Nov 3, 2006
    rockinrepair, Vit@liy, ammdb and 2 others like this.
  7. tochatihu

    tochatihu Senior Member

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    Thanks a lot for posting the details. Let all who read this thread know that if you do something really bad to the 12 volt circuit, your Prius will be dead until fixed in this way.

    This is of particular interest for jump-starting other vehicles: be sure, as never have been before, that you have the polarity right. Couldn't some other car be used as a donor instead?

    Also for those who add a 110 vac inverter (as I have). Please learn about adding another, smaller 'sacrificial' fuse ahead of this hard-to-change thing. Then you'll be able to drive home afterwards...
     
    #7 tochatihu, Nov 3, 2006
    rbdigital likes this.
  8. BetoLgrande

    BetoLgrande New Member

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    #8 BetoLgrande, Jul 29, 2013
  9. BetoLgrande

    BetoLgrande New Member

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    Wow...I just got a 2002 Prius with 60 k original miles. The car was sitting on a garage for a few months with bearly any use. When I first drove the car was perfect and on my way back home on the hiway the car die on me and shut off. I just jump it and stated again. The next day the car was dead again. Today I just bought a new battery but the car did not start, not a single light.
    I check the fuses and the 100 a and three of the 15 a fuses were blown.
    I got the fuses but the 100 a fuse is the hard one to remove.
    I hope following this directions I will get to it.
    If by any chance you have some pictures or diagrams that would help me no to mess anithyng will be apriseated..
     
    #9 BetoLgrande, Jul 29, 2013
  10. oldnoah

    oldnoah Member

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    Does anyone know what he's calling the "aquarium cover?"
     
    #10 oldnoah, Jan 14, 2014
  11. Ryan MacDonald

    Ryan MacDonald New Member

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    This howto helped me a ton. Thank you.
     
    #11 Ryan MacDonald, Dec 6, 2019
  12. ammdb

    ammdb Active Member

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    #12 ammdb, May 31, 2020
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