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Loose Fuse FINAL Fix

10475 Views 3 Replies 4 Participants Last post by  FrEaK_aCcIdEnT
So I've had an ongoing issue with my truck since purchase about two years ago- the passenger's side headlight going dim or not illuminating at all. I've diagnosed it to be the fuse, which is loose in its location. What I had done was slightly bending the prongs on the designated fuse, so it would have a snugger fit.

The problem is that every now and then, the fuse either blows from slight arcing within the fuse slot, or it works itself loose again. I'd assume that at one point or another the previous owner (or as I like to call him/her 'previous moron') they stuck a multimeter prong or something down there to shove and bend the contact point over. I'm at the end of my rope, and I just want to fix this mess. Should I attempt to move the contact point within the fuse block, even though I can't see the contact point or should I just buy a whole new fuse block and replace it?
Or can the knowledge of the 'nation provide me with a more creative solution?
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If you can't see the contact point you could possibly make it worse. I haven't seen the bottom of the fuse block. Maybe you could get access from that side?

The Service Manual provides the part numbers for most of the connector terminals, but nothing in regards to the fuse block. The cost of a new fuse block, at $312.91, US DEaler price, would be nearly prohibitive in Canada. BLOCK-UNDERHOOD BEC. Fits: CANYON, CANYON Crew Cab, CANYON EXT CAB, CANYON EXT LENGTH, COLORADO, COLORADO Base, COLORADO Crew Cab, COLORADO EXT CAB... | Nalley Buick GMC Brunswick

Maybe you could find one in a junk yard. I don't know what differentiates the fuse blocks from one year to the other, except the size changes of the relays from "Mini" to "Micro". It appears that the part number of the block (25933296) was only applicable to the year 2008.

Ebay might also be a good source. 2008 Chevy Colorado Fuse Panel Block | eBay
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Here is a very easy fix which I have used over the years.

Get a soldering iron.

Lay fuse on its side.

Heat up soldering iron.

Add some solder to the leg of the fuse. Build up a bit on both sides of need or on just one side.

Once cooled do a test fit when tight you are done.
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I have a couple loose fitting fuses. My fault... I used a multimeter prong to test. Forced it into the fuse slot slightly which spread the connectors out inside the fuse slot. I haven't don't it yet, but I have been told that you can unhook the fuse box, pull it out, open it, and squeeze the female side back together. If you go that route, take pics!!!

I did as you did. Just slightly bent the male side to get a snug fit.
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