mk2 galaxy electric problem battery junction box

[chap]

my old boy bought a 03 plate galaxy tdi last week run it a day and the alternator went so got one put on it now he's got no electric windows and the black box next to the battery with some wires in the wire closest to the battery is getting hot any suggestions please.

[daddyfixit]

the black box is an extra fuse box; it gets very hot/melts due to poor connection of the wire from the alternator---clean it up with emery paper to see if it cures it.  the electric windows may not be caused by this, instead the wires in the drivers door loom break and need repairing---see faq section for step by step pictures.

[insanitybeard]

As above, the battery junction box is one of the frequent issues with these vehicles, have a read here.

Door loom wiring repair info. here.

[jaredgrice1]

Late in on this but just make sure that the earth cable has a good grounding as have known that black box to catch fire. You will need to make sure that the regulator on the alternator isn't kicking out too much voltage or amps too. Only tends to be second hand or reconditioned ones that can do this. They'll pickle your battery & can cause the battery to explode if not careful. Halfords can be helpful to blag a free alternator test from.

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[jaredgrice1]

That's all earth cables not necessarily the battery one but the gearbox & starter ones & others scattered around the engine bay, inner wings.

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[johnnyroper]

Battery fuse box getting hot and burning out is due to corrosion in the alternator to box cable connector causing high resistance. Also the large cable to internal fuse box suffers same issue.

You will probably need to change the box and at very least  cut connectors off and solder new ones on. The alternator one might need changing if core is damaged.