Failed early fuse box?

So i'm having a bit of fun with my 81 GLi at the moment (pre CE1, ceramic fuses)…

I've always had problems with the fusebox, but usually cleaning the relevent fuse has sorted the issue. a couple of months ago to try and end the problems i removed the fuse box, removed all fuses, cleaned every terminal and reassembled, and it worked spot on.

A couple of weeks ago i realised the wipers, heater and heated rear window were dead, the relevent fuses are dead on both sides.

I have removed the fuse box again today, checked the connections, cleaned everything and reassembled, and i still have the same problem. The heater connections at the back of the fuse box show signs of heat. Everything else works perfectly, there is power at the spade terminals along the top of the fuse box on the back (i imagine these are split permanent live and ignition live?, the diagrams i've been using from cabbyinfo don't detail these).

Anyway, i'm thinking something inside the fuse box has blown? Not quite sure!

 

Well the inside of a fuse box looks like a maze on speed.
or Ludes…



New or repo ones are available vwheritage used to list them.

But the error that you are describing is more to me related to the X circuit, and the load reduction relay.  The common point of failure is the relay, or the ignition switch.

My buddy Ron has a thread on this,
The "X" Circuit from the Ignition Switch. | VW Vortex - Volkswagen Forum

If everything downstream of "X" on the ignition switch, that is headlights, HVAC fan, wipers and rear defogger are all inoperative, it is reasonable to assume that "X" on the ignition switch itself has failed.

He goes in depth on how to diagnose it.  

Is it the X circuit, or the ignition switch?

The quirk I forgot to include. It's curiously interesting, knowing about it can aid in quickly diagnosing issues with these circuits.

Key in your pocket, switch the headlights, wipers and HVAC fan. None should run, park lamps should be on.

Now pull and hold the headlight high/low beam switch on the turn signal stalk. Nothing happens? Release and pull it again.
Every other pull of the high/low switch with the other switches on as described should result in the wipers and HVAC fan running as long as the high/low switch is held.

Headlights should come on with every pull and hold, regardless is the other switches are on or not, headlights will be high beam only.

If they don't work with the key in, I would suspect the ignition switch.

Oh now that is interesting, i didn't even realise that circuit existed!

Going from that thread, since my headlights work it would suggest the circuit has failed on the relay side (hopefully the relay!).

Looking at the fuse and relay panel diagram the second in from the left is the load reduction relay, which my car does have fitted (a short silver relay).
I will investigate tomorrow morning!

Well it seems, fingers crossed the relay has failed.

Theres power at the correct two terminals, and bridging the switched live makes the heater, wipers and rear window work. So it looks like it!

New relay is ordered, will report back…

easier to replace than the Fuse Panel.   glad to be of service.