melted wiring

[audi0704]

Hi all I;m hoping some-one can point me in the right direction with an electrical problem I had a couple of nights ago as I pulled onto the drive I thought the headlights seemed to brighten for a split second as if they had gone onto main beam,switched lights off and smoke poured up from the steering column shroud.
I immediately switched the engine off and after a couple of seconds the smoke stopped thankfully,removed the covers the following morning to find a wire either grey/black or grey/red which runs from the indicator/main beam stalk to the fuse box therefore the full width of the cab had melted completely.
I have opened up the harness and replaced the wire checking all other wires it came into contact with taping up slightly scorched areas and renewing anything suspect,there are no outward signs of burning or sticking contacts on either the light switch or the indicator stalk and everything appears to be working fine now.
The issue is how can 2 to 3 metres of wire melt to such a state that I can't say for sure what colour it was and NO fuse blew,also I can't find what actually caused the problem and because of this I am thinking of fitting an inline 10amp re-settable thermal fuse in the replacement wire.
Anybody any thoughts on the original problem or my intended makeshift remedy with the thermal fuse as I am a bit unsure on using the van until I can be reasonably sure it isn't going to burst into flames.
Cheers bob

[California Dreamin]

Have you got a non genuine steering wheel fitted? just a thought as sometimes this is known to be an issue.
I think the idea of fusing this wire is a good one, certainly can't hurt.

Martin

[audi0704]

Hi martin thanks for the prompt reply and yes I did have an audi steering wheel fitted,so where does the problem arise is it something to do with the horn wiring as the horn was not working with this wheel fitted ?
Very intrigued to know what I've done wrong.

[California Dreamin]

Indeed.....the contact ring being too close and shorting out terminals on oposite side....sometimes catching the 3 switchgear retaining screws.
I've had a MK1 GTI & now a Momo on mine...you have to be very careful and aware of this particular issue. Trouble is, the air gap changes in size as the wheel is turned so an apparent gap can then disapear.

Martin

[kevtherev]

straying from standard... tut tut

When electrical equipment is involved, one must be doubly sure that it's safe
I allways ask here before changes are made.

jus' sayin'

[audi0704]

Thanks martin i'll have a close look at that,the original bus size wheel is going back on for now as MOT is due and obviously need the horn working,do you have any suggestions for an alternative smaller wheel as I am experimenting with different drivers seats and the one fitted at present out of a Scooby is higher than the original and a bit of a squeeze getting MY FAT OLD CARCASE past the BIG OLD VW steering wheel.
Cheers for pointing me in the right direction
Bob

[audi0704]

straying from standard... tut tut

Weakness of mine kev done it all my life but point taken just never saw the connection (no pun intended)
cheers bob

[Funkyoid]

Did you get the non standard wheel fitted in the end? My friends horn didn't work and hasn't for ages, since she bought the van. It went to a garage for the MOT, and it failed so they fixed the horn, it just wasn't wired in. Since then something has been draining the battery and I presum its the horn. We also presumed the van had a standard steering wheel but it might not do and therefore this might be the reason why its draining the battery??? It may also explain why the horn was never actually connected in the first place (was bought like that - not us!).

It is a VW steering wheel, so maybe off a smaller vehicle - can anyone then tell me what to do if I find it is indeed the steering wheel causing the issue other than temp disconnect the horn and maybe put a switch in for the horn on the dash? How do you stop it shorting? If we bought a standard steering wheel and fitted it (presuming we find that the horn is the drain - can't see what else it can be seeing as it was fine before it went to garage and now it is not) would this solve the problem?

Any help would be really appreciated as I am only there tonight and tomorrow although I could go again the following weekend (I live in Scotland but my friend and her van are in Bolton!!).

Thanks,

Beckie

[slowcoach]

Maybe search ebay for t25 wheels, and see if your friends matches the pictures?

I don't know about alternative steering wheels, but i guess you've disconnected the horn wires under the bumper, to see if you still get the battery drain?
Good luck!

[audi0704]

I ended up re-fitting the original wheel as my MOT was due and needed the horn working,MOT now passed I am going to fit a VW polo G40 steering wheel and if as with the Audi wheel the horn doesn't work I will re-wire it to a momentary push switch on the dash,thinking also of biting the bullet and going for electric power steering,anybody got views on this ?
Cheers bob

[Funkyoid]

Just like to say we managed to get the drain and steering wheel and horn fixed. One of the contacts was shorting inside the steering wheel. I made a little sleeve thing to go over the contact to stop the short - hey presto it worked.

So no battery drain, and steering wheel and horn all ok - result!