Hello All,

I have a beloved 240GL which has what is apparantly a "classic" 240 problem: corrosion of the fuses at the drivers feet leading to starting problems. This has been a problem in rainy times ever since I got the car 5 years ago. My solution was either to twiddle the fuses, or to replace the fuses and clean the contacts with sandpaper. Until this year, this always worked. Several times in the past month however, I've been left stranded when the car wouldn't start, and no amount of twiddling would help. I then replaced all the fuses, using Buss glass fuses for some of the positions, and dremeled the contacts to a shiny surface. After adding the fuses, I sprayed wd-40 to "prevent corosion". The car started fine and was ok for a day. Then this morning, the car wouldn't start again. I looked more closely at the fuse panel again and saw that there was a lot of corosion on the back of the panel. I especially noticed the number 7 fuse (fuel pump) back connector was green. So (after some challenges to unscrew the fuse panel), I cleaned the spade and replaced the female connector. I sprayed wd-40 on the whole back pannel to again "prevent corosion". I put everything back together, although the fuse panel wasn't screwed in as tight as it could be. But the car fired up immediately so I was very happy. I drove to work and 3 minutes into the trip the car died at the light. After much praying, fuse twiddling and key turning, the car started and I limped home.

Any suggestions of next steps? I was thinking about getting a new fuse panel, and changing all the female connectors at the ends of the wires that connect to it. Was the wd40 a mistake? Was the panel not being tightly screwed in a mistake?

Any suggestions greatly appreciated!