Contents
This kit allows the X or Frontier owner to add up to 20 (depending on kit purchased) extra fuse protected circuits to their vehicle. If you have ever tried to add two sets of lights then a CB and finally maybe a high power stereo amp you quickly run out of places to tap into power and ground! What you end up with is a mess of wires under the dash, attempts to tap into the existing fuse box and fuse holders everywhere. Then when it comes time to find which fuse blew, you spend 20 minutes tracing wires! (Of course, you didn’t label the wires! real men don’t …) Having gone through this many times I put together a kit to once and for all get rid if this problem! Fig 1 shows the result.
Fig. 1
Included Parts list:
1 10 circuit 100 amp Fuse Panel with ground terminals
1 100 amp manual reset with manual trip circuit breaker
1 Pre-assembled 6 ga power lead with wire protector loom
1 Pre-assembled 10ga ground leads with wire protector loom
2 7.5, 10, 15, and 30 amp fuses.
1 20 amp fuse
1 Mounting bracket with screws and nuts
10 Red 14-16ga wire terminals for connecting low current devices to fuse panel
5 Yellow 12-10ga wire terminals for connecting high current devices to fuse panel
Tools Needed:
1. 10 mm wrench for battery hold down bracket nuts
2. 12 mm wrench for Alarm Horn nut and battery + terminal nut
3. 3/8” socket for nuts on fuse panel
4. 7/16” socket for nuts on circuit breaker
5. 10mm socket for removing bolts for ground terminal
6. Screwdriver to secure bracket to Fuse Panel
Before you start: Place vehicle in a well lighted area, set the parking brake and raise the hood.
1. Using the 10mm wrench remove the nut on the battery hold down bracket closest to the power steering pump reservoir
2. Place the circuit breaker over the hold down bolt as shown in Fig. 2. Place a washer over the bolt then put the nut back on. Leave the nut loose for now.
Fig. 2
3. Using the 12 mm wrench remove the nut from the back of the security horn as shown in Fig. 3. Leave the horn attached to the bracket.
Fig. 3
Fig.4 (Alternate Fuse Panel Mounting)
4. Attach the bracket to the Fuse Panel using the supplied nuts and bolts. See Fig. 4
Fig. 4
5. Mount the assembled fuse panel to the horn bracket using the nut you removed in step 3.
6. Loosely attach one end of the long 6ga cable to the power mounting stud on the fuse panel using the supplied nut. Do not tighten yet! Se Fig 5.
Fig. 5
7. Loosely attach one end of the 10 ga cable assembly to the grounding stud on the fuse panel using the supplied nut. See Fig.6.
Fig. 6
8. Route the other end of the 6 ga cable along the inner fender, under the – Negative battery cable and loosely attach it to the Aux Post on the circuit breaker as shown in Fig. 7.
Fig. 7
9. Loosely attach the other end of the 10 ga ground cable under one of the two bolts shown in Fig. 8.
Fig. 8
10. Press the red button on the circuit breaker so that the breaker is tripped. A little lever will pop out as shown in Fig. 9.
Fig. 9
11. Loosely attach one end of the short 6 ga cable to the BAT post on the circuit breaker. Remove the red plastic cover from the + Battery terminal. It just pops off. Bend the wire in a loop as shown in Fig. 10.
Fig. 10
12. Using the 12 mm wrench remove the nut on top of the +Battery post. Place the other end of the short 6 ga cable under the nut and loosely tighten it. See Fig. 11.
Fig. 11
13. Using a sharp knife notch the right side of the battery post cover so it will close over the wire. See Fig. 12.
Fig. 12
14. Now position all the wires where you want them and tighten them all down. You need to tighten the Battery post nut, Bat. post on Circuit Breaker, Aux. post nut on Circuit Breaker, power mounting stud on the Fuse Panel, ground stud on the Fuse Panel and ground connection bolt to chassis.
15. Reset the circuit breaker by pressing the lever back in. You now have power to the Fuse Panel!
The Circuit Breaker/Disconnect Switch
Facts about the breaker
The circuit breaker is rated for 60 or 100 Amps depending on which kit you purchased. It is for protecting the fuse panel and the wire connecting it to the battery, NOT the devices plugged into the panel! It will trip if a current exceeding 60 to 100 amps (depending on kit) passes through it. This could happen if you have the fuse panel fully populated and ALL the devices connected are pulling full power and are turned on at the same time. This scenario is not likely to occur in real life. Another cause could be a dead short that occurs in the 6 ga wire connecting the circuit breaker to the fuse panel. If this happens the little lever will pop out, indicating there was a short. Find the cause of the short BEFORE resetting it!
Using the breaker as a disconnect switch
By pressing the red button on the top of the breaker you force a manual trip. This opens the connection between the battery and the circuit breaker. This is handy! Anytime you are working on ANY of the fuse panel circuits or are adding a new one just push the button to disconnect power. A simple press of the lever will restore it!
The Fuse Panel
Facts about the fuse panel
I supplied a variety of fuses that should cover most of your needs. However you may have 10 5 amp devices you want to connect! Just replace the fuses with whatever your needs are. The fuses are available at any store that sells auto parts. They are ATC style automotive blade fuses.
See the Fuse Selection Table page for help in determining what fuse you really need to protect your device. Each fuse has a ¼” tab connector for connecting your device. Use the appropriate size wire and connector for the current the device will draw. See the Wire Selection page for help in this area.
Contact Information
Email: coolerman@qx.net with any questions or suggestions. I am always looking for new ideas!