D2 td5 fuse blowing issue

[Squanderer]

My auto trans TD5 1999 model D2 keeps blowing fuses. It started nine months ago shortly after I had the transmission taken out and reconditioned (and reinstalled twice after it wasn't right the first time). First happened in remote Qld after a creek crossing and a rough track (wasn't the first water crossing though on that trip), then persisted after seeing a mechanic in Longreach with much head scratching (great bloke though) and kept going on drive to Brisbane. Each time the M& S lights came on first, then if I stopped and turned off the ignition, often I would have to replace at least one fuse (mainly F22 under dash) and press the diesel cut off switch under the bonnet to restart

Taping various parts (random, in frustration) of the wiring which runs to the transmission from the gear selector, underneath the car, seemed to help. No problems for 1500km until recently, when the M &S lights kept coming on each time I went over a large bump on the M1 going to Albury, but no blown fuses. Restarting cleared the S &M problem (much better description than M&S!). Now I am back to blowing fuses, whether going over a bump or just driving, as well as the preceding M&S issue..the fuses have either blown while driving or when I try to restart, I'm not sure which.

The persistent culprits (under the dash) are 10A F22 (lights? symbol?) and 10A F24 (engine? symbol) (I may have these symbols/F nos the wrong way around). In Qld I also blew the under bonnet fuses F1 (30A engine symbol?), F10 (30A fuel symbol) and F13 (10A battery symbol) once, but not since then.

My mechanic here in Sydney has suggested replacing the wiring harness to the transmission (he can only get it 2nd hand) but i was wondering if anyone had any further thoughts before I do this? I have zero electrical aptitude; can't use a multimeter. No obvious breaks in the under car wiring though!. The issue is always preceded by the S &M lights coming on first and going into limp mode. It has made me stick to my D4, which while great isn't my preferred very remote travel vehicle.

cheers
Squanderer

[PhilipA]

It's known that the transmission harness will chafe where it crosses over the top of the transmission tunnel . More precisely as it turns towards the transmission from the top of the tunnel. There is a steel clamp there which wears through the outer insulation and two wires can lose their insulation and touch at times. ( or just on the sharp corner of the trans) There was a post on here a few years ago where it showed the loom unwrapped and the bare wires.
It's hard to see unless you remove the console and the console top by drilling out 14? rivets and there it is. I added some corrugated loom cover to mine.
Regards PhilipA

[sierrafery]

Hi, i really doubt that the transmission harness would blow any fuse as it's not directly connected to the fusebox. I'd replace the interior fusebox first if i was you cos they commonly suffer by corrosion inside which can cause a huge variety of symptoms. F22 is for the RH main beam it has nothing to do with the transmission nor those fuses from the engine bay, the only one which is connected to the autobox ECU is F24 but this one is also connected to the alternator so when it blows the M+S light are coming on due to low voltage. I suspect some short circuit within the interior fusebox hence it blows those from te engine bay too. If it's not that the vehicle's main harness which contains the fusebox's connectors is more suspect than anything else. You should rule out that fusebox before you go further, it's plug and play, important is to be from same modell(non facelift in your case), to disconnect the battery negative lead before the swap then after reconnection turn ignition on 2 and leave it so 5 minutes without doing anythig else. Good luck, you'll need it cos it's a very strange fault as there is not much connection between those blowing fuses.

[Squanderer]

Thanks Philip. I hadn't considered the inaccessible bit and had only tackled the area near the bolt on bracket. Time to pull it out and properly inspect it

cheers
Squanderer

[Squanderer]

Thanks very much Sierraferry; an interesting possible solution. In terms of the M & S lights coming on, this is always the first symptom and the car always goes into limp mode (sometimes with no blown fuse that I am aware of), so I guess the query there is whether the fact of the F24 fuse blowing would also trigger limp mode, or just the M & S lights showing?

I have looked into 10p/1999 model suitable/fuse boxes; it seems they don't make them any more so I will have to go second hand. Hopefully with a red fuse puller (I managed to lose mine)

I know from reading posts on this forum that there are about 18 reasons for the S & M lights to come on; I may have found the 19th....

cheers
Squanderer

[sierrafery]

Depends on what fault code is logged in the autobox ECU