Fuse Box - Engine Bay

Removal and replacement of the engine bay fuse box (Power Distribution Center) on a 1992 Dodge Viper, including disconnection of all electrical connections and mounting hardware.

Warnings

Tools required

Parts

• Fuse box assembly (Power Distribution Center) × 1 — Use OEM specification
• Fuse box cover × 1 — Use OEM specification (if damaged)

Preparation

1. Park vehicle on level ground and ensure engine is completely cool
2. Turn ignition off and remove key from ignition switch
3. Open hood and secure with prop rod
4. Photograph the fuse box and all visible connections for reference during reassembly
5. Disconnect negative battery terminal and secure cable away from battery post

Procedure

1. 1

   Remove fuse box cover
   Release the retaining tabs on the fuse box cover by pressing inward on each side. Lift the cover straight up and away from the fuse box housing. Inspect the cover for cracks or damage to the retaining tabs.
2. 2

   Document fuse and relay positions
   Take a clear photograph of all installed fuses and relays in their current positions. Note any missing fuses or relays. If replacing the fuse box, you will transfer these components to the new unit. Reference the fuse diagram on the underside of the cover for circuit identification.
3. 3

   Remove fuses and relays
   Using needle-nose pliers or a fuse puller, carefully remove all fuses and relays from the fuse box. Place them in labeled containers or bags corresponding to their original positions. This prevents confusion during reinstallation and protects the components during fuse box removal.
4. 4

   Disconnect main power feed harness
   Locate the main power feed connection on the fuse box assembly. Verify against the vehicle service manual whether the main feed is a plug-in connector or a bolted B+ stud, as the 1992 Viper Power Distribution Center may use a threaded stud connection rather than a snap connector. Remove or disconnect it per the appropriate method, taking care not to damage the terminal or post.
5. 5

   Disconnect secondary electrical connectors
   Identify and disconnect all remaining electrical connectors attached to the fuse box. Refer to the factory wiring diagram to confirm the number and location of connectors on the 1992 Viper Power Distribution Center. Depress the locking tabs on each connector and pull straight out. Note the orientation of each connector for reinstallation.
6. 6

   Disconnect positive battery cable at fuse box
   If the positive battery/main feed cable terminates directly at the fuse box (verify against the service manual, as this may be the same connection described in step 4), remove the terminal bolt using the appropriate socket. Carefully lift the cable terminal away from the fuse box post. Inspect the cable terminal and post for corrosion or damage.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
7. 7

   Disconnect ground strap if present
   Check for any ground straps connected directly to the fuse box mounting bracket or housing. If present, remove the ground strap bolt and set aside the strap and hardware. Clean the contact surfaces with a wire brush if corrosion is present.
   Torque spec

   Ground Strap Bolt14 Nm (10 lb-ft)
8. 8

   Remove fuse box mounting bolts
   Locate the mounting bolts securing the fuse box assembly to the inner fender or mounting bracket (verify the exact count and pattern against the factory service manual). Remove all mounting bolts and retain them with their washers if present.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Remove fuse box assembly
   Carefully lift the fuse box assembly straight up and away from the mounting location. Guide any remaining wiring harnesses clear of the mounting bracket. Inspect the mounting bracket and surrounding area for corrosion, damage, or debris. Clean mounting surfaces if necessary.
10. 10

    Prepare new fuse box
    If installing a new fuse box, compare it to the old unit to verify correct application. Transfer any additional components such as circuit breakers or special relays that may be mounted externally on the old unit. Inspect all terminals and connection points on the new fuse box for damage or corrosion.
11. 11

    Install fuse box assembly
    Position the fuse box assembly over the mounting bracket, guiding the wiring harnesses into position. Align the mounting holes with the bracket. Install all mounting bolts (verify count against factory documentation) finger-tight, then torque evenly to specification to ensure the fuse box seats against the mounting bracket.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Reconnect ground strap
    If a ground strap was removed in step 7, clean both the strap terminal and the mounting surface with a wire brush or contact cleaner. Position the ground strap and install the bolt. Torque the ground strap bolt to specification to ensure proper electrical grounding.
    Torque spec

    Ground Strap Bolt14 Nm (10 lb-ft)
13. 13

    Reconnect positive battery cable
    Clean the positive battery cable terminal and the fuse box post with a wire brush if any corrosion is present. Position the cable terminal onto the fuse box post, ensuring full contact. Install the terminal bolt and torque to specification. Do not overtighten as this can damage the terminal or post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
14. 14

    Reconnect electrical connectors
    Reconnect all electrical connectors to the fuse box in reverse order of removal, starting with the secondary connectors and finishing with the main power feed harness. Ensure each connector seats fully and the locking tabs engage with an audible click. Verify correct orientation using your reference photos.
15. 15

    Reinstall fuses and relays
    Using your documentation from step 2, reinstall all fuses and relays into their correct positions in the new fuse box. Ensure each component seats fully into its socket. Double-check positions against the fuse diagram on the cover.
16. 16

    Reinstall fuse box cover
    Position the fuse box cover over the fuse box assembly, aligning the retaining tabs with their slots. Press down firmly until all tabs engage with an audible click. Verify the cover is seated evenly around its entire perimeter.
17. 17

    Reconnect battery and test
    Reconnect the negative battery terminal and torque the terminal bolt to specification. Turn the ignition to the ON position (do not start the engine). Verify that instrument cluster indicators and gauges power up as expected for this vehicle. Check for any unusual odors or smoke indicating a short circuit.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Installation follows removal in reverse order
2. Ensure all electrical connections are fully seated and locked before reconnecting battery
3. Verify all fuses and relays are installed in their correct positions per the fuse diagram
4. Torque all fasteners to specification to prevent loose connections or overtightening damage

Verification

• Turn ignition to ON position and verify all dash warning lights function normally
• Start engine and verify it runs smoothly without any electrical faults
• Test all major electrical systems: headlights, turn signals, horn, wipers, and cooling fans
• Check for proper alternator charging (battery voltage should read 13.5-14.5V with engine running)
• Inspect fuse box area for any signs of smoke, unusual odors, or overheating
• Verify fuse box cover is securely installed with all retaining tabs engaged

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle