425 fuse holder failure

washita · Dec 24, 2011

finally found the problem with the stalling and the rough idle, the fuse holder back by the motor has a scotch lock style fuse holder (this style was banned from the automotive industry over 5 years ago) this intermittent problem had persisted all summer, I originally suspected poor fuel quality, then suspected a weak coil on the ignition system, I even replaced the ignition switch, finally due to process of elimination and ''dumb luck'' the ''wiggle test'' found it, I beleive the vibration of the motor kept electrical contact active

BobRip · Dec 24, 2011

I had the same failure. Very bad designed fuse holder.

Clumber · Dec 25, 2011

Please post how to solve the problem. Can the fuse holder be easily replaced?

BobRip · Dec 25, 2011

Clumber said:
Please post how to solve the problem. Can the fuse holder be easily replaced?

Very easy to fix. But it was erratic at first. This made it hard to diagnosis. Mine in a 422 was wired to the big positive terminal on the starter. It was only a few inches from this terminal.

washita · Dec 25, 2011

the plan is to replace the failing fuse holder with a ''marine grade'' fuse holder which is waterproof. The new fuse holder and fuse are physically smaller, but with the same amperage capacity, after the holidays are over I will have a chance to work on the 425, until then it is stranded back in the woods where I was working, will post pics when completed

cqaigy2 · Dec 25, 2011

Good find! :thumbsup:

Can you post a pict of your fix?

BobRip · Dec 25, 2011

cqaigy2 said:
Good find! :thumbsup:

Can you post a pict of your fix?

I have had two of these fuse holders fail if memory serves me right.

washita · Dec 29, 2011

replaced the fuse folder with an ATC Splash Proof Fuse Holder #12 Lead Wire, 30amp Max part # BP/HHG-RP
took about 10 minutes to change the fuse holder I also used heat shrink butt connectors to seal against corrosion and moisture, attempted to take pictures of the repair but the weather was too overcast to distinguish the new fuse holder from the rest of the wiring in the harness, when I get it into the shop with better lighting I will retake pictures, also note this same style of fuse holder that failed is used on the hydraulic cooling fan circuit I plan to change that one in the near future, of side note the failed fuse holder states ''max. fuse 20 amp'' mine had the original 30 amp fuse in it , we have all put a penny behind a blown screw in style glass fuse haven't we :ashamed::ashamed::ashamed::ashamed:

BobRip · Dec 29, 2011

wa****a said:
View attachment 243774

View attachment 243775
replaced the fuse folder with an ATC Splash Proof Fuse Holder #12 Lead Wire, 30amp Max part # BP/HHG-RP
took about 10 minutes to change the fuse holder I also used heat shrink butt connectors to seal against corrosion and moisture, attempted to take pictures of the repair but the weather was too overcast to distinguish the new fuse holder from the rest of the wiring in the harness, when I get it into the shop with better lighting I will retake pictures, also note this same style of fuse holder that failed is used on the hydraulic cooling fan circuit I plan to change that one in the near future, of side note the failed fuse holder states ''max. fuse 20 amp'' mine had the original 30 amp fuse in it , we have all put a penny behind a blown screw in style glass fuse haven't we :ashamed::ashamed::ashamed::ashamed:

Now I remember. The fan fuse holder was the other one I replaced. I also tie wrapped the two fuse holder leads together to keep them from vibrating out of phase and stressing the internal connections. If PT had done this the fuse holder would probably have lasted a lot longer.