Hello,

I have a leak that drips onto the fuses at the left kick panel. Has anyone experienced this? Did you find a source?

I snaked the sunroof drain that goes through the A-pillar and it was clear, though I haven't poured water through it.
I did water the car from the ground up and seemed to blame the windsheild. Duct taping the windsheild seemed to do it but revisiting that later by retaping for a rainstorm wasn't so convincing...it leaked. Not the original windsheild.

Your thoughts?

The leak may be coming from just up above the fuse box where several body panels meet and are spot welded with some sealer gunk on the seam. You can't really reach up inside and do anything about it. I had a similar leak on the passenger side of my '86 240. I found the the water was getting in from the drain holes under the rubber molding around the windshield.

If you pry up the molding near the lower corners of the windshield, you should see small drain holes which are supposed to take water which gets under the molding and drain it down into the same drain which takes water from the air intake and runs it down eventually to the rocker panels. Apparently, if those welds and seals that I mentioned above leak, the water from these drains goes inside the car. This is well known to cause fuse corrosion problems in the 240s.

There are two things you can do. First, clean the fuse ends and the fuse clips thoroughly. I disconnect the battery and then scrub the clips with a small wire brush. Lightly coat the clips and fuse ends with silicone grease (SylGlide) and reinstall, tightening any fuse clips that seem loose.

Next, you can do as I did and seal those drain holes under the rubber molding. I talked it over with the glass shop I use and they said to use Urethane caulking NOT Silicone since the Silicone causes problems if you ever have to replace the windshield. In fact, the sealed the whole drain channel for free! After that, I had no more leak.

Good luck. You should at least clean and grease the fuses or you will have electrical problems as the fuses corrode. BTDT

Thanks a lot Jim and to everyone.
TB

Yeah, exactly, everything you said.
My wife just took my 92 down to VA Beach, a 1000-mile round trip from here. It was fine the whole time. On the way back, major rainstorms on the east coast. MAde it back without issue. The next day, after driving a couple times, it would not start in the driveway.

Pulled and inspected fuse 6. The metal was intact... but the blue plastic or ceramic was melted back into the fuse... the metal cap was compressed right through it.

Each fuse showed white corrosion and required re-cleaning. I need to silicone-grease the whole box.
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Rob Bareiss, New London CT ::: 92 244-M47-208K ::: Bilsteins, Turbo swaybars, Virgos, Lowered, Group A wing, Tach, 6-Disc, Satellite Radio, Keyless Entry ::: Coming Soon: B-Cam!

And everyone likes to blame the Eurofuses instead of the water leaks. Is this a problem in VW's as bad as it is in 240's? Water follows wires without drip loops no matter what the badge says.

Mine leaked there. I solved it by reseating and checking the tubes that go from the car dor to the body. (Carry the wires). Mine had been pushed in all the way. They should make a good seal at the end.