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  Drain holes
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Cleaning the drainage channels and protecting the fuseboxes from water ingress

We have had many reports of Scorpios not starting or exhibiting erratic behaviour which has eventually been tracked down to water ingress into the fuse and relay boxes. The Scorpio has a main and auxilliary fusebox, mounted at both sides of the area below the windscreen. Although both boxes have a clip on lid with foam seal, that are effective at keeping out water, they are not designed to sit in several inches of water caused by waterlogging. There are two issues in this area: the battery cover (which protects the top of the fuseboxes from water running off the windscreen - and the Drain Holes, which allows the same water to leave the battery shelf area and keeps it dry.

The fusebox is constructed from layers of coppersheet separated by Mylar sheets and water getting inside starts rapid corrosion and shorting. One RAC patrolman reported that he had seen several Scorpios 'fizzing' from their fuseboxes.

Where the battery cover has been lost - this is absolutely essential on every Scorpio and a replacement must be fitted immediately. If it's missing remedial action must be taken to remove any moisture from the fusebox. Covers are not expensive (approx 8+vat) and can be ordered from any Ford Main Dealer. Without it, water falls from the opened bonnet directly onto the fusebox.

This is battery cover that MUST be fitted to every Scorpio. If it's missing get a replacement from your Ford Main Dealer as soon as possible, check for water in the fusebox and get it dried out and check that the drain holes are clear.
Without the cover you can see that water soaks the Auxilliary Fusebox - this may be the start of major (and expensive) problems shortly. Look at the bottom of the battery shelf and check that water is not pooling there.
Here you can see the problem with the Main fusebox which does not have a secondary cover - water drops from the opened bonnet directly onto it. Make sure the lid is firmly clipped in place and check the drain channels beneath it. If water is puddling at the bottom of the shelf get the drain holes clear as soon as possible.
The Main Fusebox shown from the front. The lid must be a tight and secure fit. If you remove it for any reason check that it is properly clipped at the rear before you engage the front clip. An error here will cause real headaches later.
With the lid removed you can see the complexity and number of relays and fuses. It's a complicated construction comprising sheets of copper separated by Mylar insulators. Damp and water can ruin it very quickly.
Drain holes are located beneath the box and must be cleaned on a regular basis. Most of the debris is from leaves etc that have washed in from the bonnet or windscreen. Even with the battery cover, if the drain holes are not kept clear the fuseboxes will end up sitting in three inches of water that seeps down the cables through the bulkhead and causes expensive damage to the electrical systems inside.
Access to the drain holes is from the front. There is a similar one located on the other side of the car for the Auxilliary Fusebox too!

Peel back the insulation and pull out the muck. A small amount of water (kept away from the box itself) can be used to clean it and check that water can run away freely.


It is best to check this area every Spring and Autumn and as part of the yearly service.


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