Hello,

My xA has gotten me through many years and many miles, but I recently went out of town to spend time with family for 2 months (since COVID meant I wouldn't be working anyway).
When I came back my battery was dead and I am not mechanically inclined, but I'm determined to learn.
To sum it up, the terminals are fused to the battery posts and need to be replaced along with the battery. I started to tackle that task myself, since it's a fairly simple place to start for someone learning to work on engines.

However, I ran into another problem. (Please bear with me while I share photos to discuss what I mean and when I use non-technical terms to describe parts I don't know the names of, heheh.)

The nut/bolt and washer and cable attachment for the positive terminal were ALSO completely fused. A neighbor who is mechanically inclined saw me struggling to loosen it and came over and the two of us
wrestled with it for over an hour and nothing either of us tried managed to remove the nut. On top of that, of course we damaged the brass bit that the nut is attached to, which is part of that black/red box.



Anyway, LONG STORY SHORT (trying to keep this succinct) I need to replace whatever this thing is called below:



I need to replace the black/red box and the ring/clamp that attaches to the cable. I've done a lot of Googling but I don't know the proper search terms to look for and I can't seem to find anything that tells me what this
black/red box thing is called so I can find a replacement part. I looked in my vehicle manual as well, and it isn't mentioned in there, either. I've been referring to it as a fuse box in my own head, but I'm pretty sure that's not what it is.

Any assistance would be greatly appreciated. Thank you!

_____

 

Update:

I've found the part number for the fusible link block (8262052011), but I can't find the name or part number of the attachment piece that links the black/red cable to the terminal. I've also tried to find the part number for the red/black cable itself, assuming that it comes with the brass part attached already, but I can't find that either.

If anyone knows what this is called or what the part number is, I'd be greatly appreciative of that information! Thanks again.

 

What Model Year & Drive line is your xA?

If you tell me the Model Year & Drive line (Manual or Auto), I can do some Research and Might be able to come up with the Part No., Price, Source, Diagram, Location.

Sticky Where to Post Your Question

I have been here Every Day for over 12 years and it Always surprises me people want Part Numbers, Parts Information or Location
but don't give out their Model Year & Drive line (Manual or Auto).
When you go to a Toyota Parts Department, or any Cars Parts or Auto Store they always want the Make / Model Year / Drive line.

Why?

Do Not Assume that Part Numbers stay the same within that Generation of Cars. Part Numbers can be Changed, Superseded,
or No Longer Available. Those Engine Parts / Interior Parts you want may be available in 2004 and Changed to a Different Number in 2006 or 2016.
Some Part Numbers are Different on Manuals vs Automatics.
Or even Worse No Longer Available for any Model Year. I can at least Cross-Reference it if you give me the Model Year & Drive line.

TL;DR If you want a Specific Part No. or Specific Answer, you need to Provide Vehicle Specifics for us to look it up.

MR LUV

p.s. I Strongly Advised Members to Add their Model Year in their Signature
See examples in the Sticky Above. Or Please State it in Each Question.

__________________

 

I Apologize. I have a 2008 xA Automatic

___

 

Based on your Original Post, as I see it, to repair your problem as you describe, you will need these Items:
(Parts can be Source on many Toyota Online Dealers or your local Dealer)

1. Fuse Box, Toyota Part. No. 82620-52011 (which you already found)
2. Positive Terminal, Toyota Part. No. 90982-05053
3. Nut, Flange for Positive Terminal, Toyota Part. No. 94151-80800
4. A New Battery (if the Positive Terminal is fused to the (+) Post).

AND..the Fun Part..

As I explain in the Engine Diagram Above, unless you are willing to pay a Pro Shop or Dealer a lot of Time and Money
to Replace your Entire Wiring Harness, I Recommend this Workaround:

Get yourself a



What I would try and do:

1. Carefully, cut off the Positive Cable just to where the Old Ring Terminal was or broken off.
2. Use Diagonal Pliers or Snips to strip off about 1" of the (+) Cable to exposed the wire.
3. Use a pair of Channel Locks or Crimping Tool to crimp the New Ring Terminal on the end.


MR LUV

__________________

 

Ooooh... crap. I was afraid of that, honestly, but I was hoping my suspicion would be incorrect! Haha. I will Google how to splice battery cables, I guess! Replacing the whole harness is definitely something beyond my ability, right now.

Thanks so much for the help!

 

Wow, thank you so much for the helpful instructions!!! I really appreciate it. I will let you guys know how it goes. :D

___

 

LUV coming through with good advice again...

 

Hmmm I am not an auto mechanic, but I played an Electrical Engineer in real life for 40 years.

WHY do you think the red box needs replacing? (I have an xB 2004 and I know that the red box is where they put the big fuses for the starter etc.)

Terminals often become corroded and difficult to unscrew, but to pronounce them "fused" seems to me to be unlikely!
And further, inability to unscrew a terminal does not mean it is not conducting electricity.

Unless I am misunderstanding something? Are those your actual pictures of your car? I just don't see anything broken.

I think if you applied enough PRESSURE (might take a chisel) right between where the battery clamp leaves come together, right on the blue copper sulfate, that clamp might well pop open.
Did you try that? Then there is the Dremel Tool option, using a small cutting wheel on the blue stuff right in the plane where the leaves meet, and going right through the bolt if you have to.

Then you could clean it with one of those battery terminal tools.

Here is the idea (of course, wear safety goggles! or googles!):


Worth a try?
:

 

I accidentally have a 2004 xA Electrical Wiring Diagram book. Here is the Red Box block representation


Red Box has BIG FUSES for everything BUT the Starter!

Unfortunately the schematic for the Red Box was split across different pages....but I think you don't need it!
Hit it hard in the right place! Sproing!

 

Hi! The photos above are from before we tried to remove the bolt. In the process of attempting to remove the bolt, the copper terminal actually ripped in two, and we really dinged up the brass bit that is part of the fusible link block, and put a dent in the black plastic in one area. And on top of that, we were unable to remove the nut/washer/lug assembly that attaches the fuse box to the positive battery cable because the nut/washer had fused to the bolt threads. Here's a photo of the "after:"



I didn't share photos of the "after" because it's a bit embarrassing, I suppose, but also because I was trying to keep my original post fairly brief and the earlier photos are clearer for me to show the bits I needed to replace. Heheh. Thanks for your help!

 

Even in that condition, to me, the heavy lug emerging from the black plastic part looks imminently repairable.
Getting that nut off without further damage is key.
Have to hold the big lug really steady, I have a BIG vice grip I would loan you if we were in the same city!
Then a LONG 3/8 or 1/2 inch drive ratchet for a lot of torque. Nut should pop, or the bolt will break! If it breaks, drill it out!
Splice to the starter cable, and find a compatible battery lug clamp that can be bolted on.
It does depend on finding someone skilled enough to jerry rig a little but the ONLY purpose of the metal is to CONDUCT ELECTRICITY!
Doesn't have to LOOK GOOD!

Looks like it might be compatible for bolting to the stump of your Red Box lug if you can get the nut off.

Otherwise it sounds like you have to Extract an Octopus!

 

Heeeyyy guys,

So MrMox asked me if I fixed my car and that reminded me to post an update, so thanks for that!

I cut the cables to remove the battery, and I was unable to remove the fuse box from the positive terminal (perhaps with a larger arsenal of tools and greater physical strength I might've been able to separate them, but... at that point it just seemed easier to install a new one), so I ordered a new fuse box as well. Took about a week to arrive. Just swapped out the fuses from the old box to the new box, stripped the cables as necessary, crimped on a new lug for the positive cable, and attached the new terminals. I did have one issue where the new lugs I ordered were too large for the cable diameter, so the crimp wasn't as secure as it could've been, but it got my car mobile and I just went to Autozone to buy an appropriately sized lug and crimped it on in the parking lot, haha. So far everything seems secure.

I really appreciate you guys' help in figuring out what parts/etc. to order! I'll definitely be back to learn more because I want to start performing my vehicle maintenance/etc. myself as much as possible.

Here are some pics of the newly installed bits, just for kicks. I put on a coating of that protectant grease stuff (after taking the photos) to hopefully help keep things from corroding as quickly or sticking together quite as firmly in the future.

 

Hello the part is called a BLOCK ASSY.FUISABLE LINK IT RUNS LIKE 35.00 TO 45.00 DILARS .