Mrs. Dependable no more

[Albert Rasner]

01 V6 mustang 240k miles dependable for last 8 years, now experiencing excessive heat from power distribution box, any ideas out there. Also having trouble starting when hot.

 

[wmburns]

Almost certainly there's either:

• water damage
• corrosion
• rodent activity
• rust or anything effecting a metal to metal bond.

Here's some information on how to located a weak electrical connection using the "voltage drop" method. But don't discount the good old visual inspection method using the "Mark I" eyeball.

Regarding the voltage drop test method of the Battery Junction Box (BJB), With the car running use a Volt-Ohm Meter (VOM) set to the volts scale. Put one lead on the battery positive. Put the other lead on each of the fuses access test "nub". Make note of any fuses with a volt reading higher then 0.250 volt. This will tell you which fuses to focus upon.

Howto perform charging system voltage drop test
https://www.stangnet.com/mustang-fo...perform-charging-system-voltage-drop-test.56/

Regarding the long crank. Try this. Turn the key on/pause/off several times without cranking. Does this reduce cranking times? If so, consider fuel pressure leak down as a possible cause.