VW Golf Dead Battery
Diagnose and fix VW Golf Dead Battery issue
Shops are finding the root problem for a VW Golf Dead Battery may be a fuse box corrosion issue, not a bad alternator as most people suspect (VW calls this a fuse bracket). The fuse box sits under the hood above the battery and can develop corrosion from road salt spray and battery fumes. As the terminals corrode, the fuse box develops excessive resistance and heat that can burn up the plastic frame, also resulting in a no-charge condition and a dead battery.
The problem fuse bracket can be found on all 1999-2006 VW Golf vehicles
Don’t automatically replace the alternator
When the fuse block corrodes, it prevent field power to the alternator and that will test out as a bad alternator if you just rely on a voltage test at the battery. If you fall for that, you’ll replace the alternator and it still won’t charge properly.
Check the alternator fuse first
The high amperage power runs through the fuse bracket before going to the positive battery terminal. If the fuse bracket shows signs of corrosion, heat distortion or insulation melting, that heat can also burn the fuse terminals.
Check for corrosion in the fuse box
If you see any signs of corrosion, heat distortion, insulation melting or fuse damage, replace the entire fuse bracket. Conduct a voltage drop test. Voltage drop under load should be almost 0-volts. A voltage drop above 0.30-volts is a sign of excessive resistance. In that case, replace the fuse box.
Replace the fuse box
Disconnect the negative battery cable and then swap in a replacement fuse box. One product is the Dorman Products 924-680. It fits the following vehicles:
2006 Volkswagen Beetle L4 116 1.9L (1896cc)
2006 Volkswagen Golf
2005 Volkswagen Beetle
2005 Volkswagen Bora (Mexico) L5 151 2.5L (2480cc); Mexico Region
2005 Volkswagen Golf
2005 Volkswagen Jetta
2004 Volkswagen Beetle
2004 Volkswagen Golf
2004 Volkswagen Jetta
2003 Volkswagen Beetle From VIN 1C3433166
2003 Volkswagen Golf
2003 Volkswagen Jetta
2002 Volkswagen Golf
2002 Volkswagen Jetta
2001 Volkswagen Golf wo/80AH/380A Battery
2001 Volkswagen Jetta From VIN 9M1081201
2000 Volkswagen Golf wo/80AH/380A Battery
1999 Volkswagen Golf
Reattach all the cables and then apply a corrosion resistant dielectric grease or quick spray of Fluid Film
Posted on by Rick Muscoplat
©, 2019 Rick Muscoplat