hi guys,

i'm experiencing this kind of problem too..except my box doesn't melting..
my fuse always trip when engine rpm reach above 3k..it is ok when idle,but not when i start to drive the car..

its only affect to the brake light,fuel and temperature gauge and also signal..and when that happen,the Charge lamp will automatically turn on..
and the fuse box also getting hot..what is the problem?is it the same problem that LeDevil facing?

Thanks.

It's happened to me too. My poor wife was in the car.
"it smells like pencils burning!!"
"why is smoke coming out of the dash?!?!"

I found a good used block and cleaned the terminals with some fine sandpaper. I also put some conductve grease on the terminals before snapping the fuses in.

If I'm not mistaken, that fuse is only for the headlights. The parking lights are on a separate circuit.

It was probably caused by a looseish type connection... They call it a HOT JOINT, i have found heaps on my ute and have been fixing up wiring all over the place... I recently just replaced the fuse box with a after market style of one, re-did all the connections as mine had melted a little also. Was some time ago that had happened though as it was sorta kinda fixed up by god knows who

Thanks David, I'll take care of that tomorrow so I can buy the stuff from work .

Yikes. I've seen them got hot enough to melt but not like that.
It may have just been a corroded connection right there. A lot of current goes through it (up to 20A), not enough to trip the fuse, but could generate enough heat to melt the plastic.

I think you can take the wire off the back, splice an inline fuse into it (like a stereo fuse, but the wire needs to be as large as the original). Just make sure to put the right fuse in (20A, not 25 or 30).

Here's the pics

Well I melted my fuse block, when I got the car I knew it had a slight headlight issue(I thought I fixed it I found a couple bad grounds) but on my way home tonight I saw smoke. I looked under my dash and BAM!!! The fuse that supply's juice to my headlights is fried. It didn't blow the fuse it just got REALLY REALLY HOTT and melted up my fuse block!! It also only gets hot when I have the headlights on. I can run my running lights all I want and it wont get warm but as soon as I hit the headlights it's getting hott. Could this be from my turn signal cam being so hokey? Or...... Could my headlight switch not be grounding out?? Any help is GREATLY appreciated as this is my Daily driver and I need it.
Thanks in Advance
LeDevil

EDIT: I will go get pics right now