123GT FuseBlock Rework
Feb 2018 R. Kwas Revisions on-going [Additional Comments]
Key steps of the rework of a FuseBlock2 of the Volvo 123GT are shown (these are substantially the same as steps for rework of FB1[which is identical to FB fitted in a 122, and 12V544], but shown here to also highlight some of the unique features and differences in the FB2).
Not shown, are specially developed tools and techniques...[I can't give away all my secrets!]
The observant reader may notice the words careful and carefully used here a number of times...this is not coincidental!
123GT FB2 core, as received...frontview...not so pretty, but all there, so a good candidate for a rework!
Rearview, with conductive commoning strap (unique to FB2 of the 123GT), which ties all source sides together, clearly evident on left. (See also: 123GT FuseBlock 2 ). Also evident are dirt and corrosion products of varying colors.
FB at the drillpress, ready for separating terminals from base.
All rivets are carefully drilled out of the brittle Bakelite housing. ...too much force, and Bakelite fractures! FB is supported just right by a specially constructed wooden fixture.
Brass terminals a carefully separated from the base. Here, some are laid out for inspection...corrosion has worked it's way between all, especially the lower terminal.
If it is not clear, from the pictures here, why these FBs require rework, here is link to discussion of the electrical reasons which it is necessary: Gas-Tight-Joint
Also, if the incoming power connection (output of the Alternator) ever were to become electrically open due to terminal corrosion, the system could be subjected to a load dump voltage surge resulting in damage. This is addressed here: https://www.sw-em.com/123GT_Reliability_Weakness_and_Simple_Improvement.htm
Intermediate Steps (not pictured):
Terminals are strung onto a wire, and blasted clean with fine media.
Bakelite base is carefully cleaned well!
Cleaned Terminals are abraded to further clean solder surfaces, removing blasting media which gets embedded in the surface, and tinned using 60/40 electronic solder.
Cleaned components laid out in preparation for reassembly. Terminals are clean, abraded in the area to be soldered, and not yet tinned. Clearly apparent is the long brass commoning strap.
Reassembled FB, before reflowing of the terminal hardware. Brass Hardware is evident.
Completed FB. All terminals have been reflowed, simultaneous torquing, and solder added to fill the Phillips heads. Frontview.
Rearview, showing additional solder from power input terminal screws to commoning strap for absolute minimum in-line resistance, and optimum monolithic gas-tight connection of all terminals. Voltage drops occurring here will be at their absolute minimum, and for a very long time!
All exposed brass is coated in Deoxit D5 terminal Treatment.
Central threaded insert gets a dab of ACZP.
FB Cover is replaced, if it was included with the returned FB.
Reworked FB is packaged, along with additional ACZP for optimum fuse installation, for return to customer.
123GT Wiring Diagram (Euro version): https://www.sw-em.com/123GT-Wiring-Diagram_Euro.jpg
123GT Wiring Diagram (US version): https://www.sw-em.com/123GT-Wiring-Diagram_US.jpg
Note: Euro and US Wiring Diagrams have differences, but not in the FB1 or FB2 areas.
This information is Copyright © 2020. Ronald Kwas. The term Volvo is used for reference only. I have no affiliation with this company, other than to try to keep its products working for me, help other enthusiasts do the same, and also present my highly opinionated results of the use of their products here. The information presented comes from my own experience and carefully considered opinion, and can be used (or not!), or ridiculed and laughed at around the watercooler, or worshipped, at the readers discretion. As with any recipe, your results may vary, and you are, and will always be, in charge of your own knuckles and future!
You are welcome to use the information here in good health, and for your own non-commercial purposes, but if you reprint or otherwise republish this article, you must give credit to the author or link back to the SwEm site as the source. If you donít, youíre just a lazy, scum sucking plagiarist, and the Boston Globe wants you! As always, if you can supply corrections, or additional objective information or experience, I will always consider it, and consider working it into the next revision of this article...along with likely the odd metaphor and probably wise-a** comment.