This procedure covers the removal and replacement of the interior fuse box (Battery Junction Box) located under the instrument panel on the driver's side.

Warnings

Tools required

Parts

• Interior fuse box assembly (Battery Junction Box) × 1 — Use OEM specification
• Wire harness retaining clips (if broken) × 1 — Assorted Ford push-pin clips

Preparation

1. Park vehicle on level ground and apply parking brake
2. Turn ignition off and remove key from vehicle
3. Open driver's door and lower driver's window for cabin ventilation
4. Disconnect negative battery terminal and secure cable away from battery post
5. Wait minimum 2 minutes for electrical system capacitors to discharge
6. Take photos of fuse box from multiple angles for reference
7. Label or photograph all accessible wire harness connectors before disconnection

Procedure

1. 1

   Remove lower instrument panel trim
   Remove the lower trim panel below the steering column. Locate and remove two 8mm screws near the hood release handle. Use trim removal tools to carefully release the panel clips starting from the bottom edge and working upward. Pull the panel away gently to avoid breaking clips. Disconnect any electrical connectors for lamp switches or other accessories if equipped.
2. 2

   Access the interior fuse box
   Locate the interior fuse box mounted on the left side of the instrument panel above the footwell. The fuse box cover should be visible. Remove the fuse box cover by pressing the release tabs and pulling outward. Set the cover and any documentation inside aside in a safe location.
3. 3

   Document fuse and relay positions
   Using your camera or phone, photograph the exact position of all fuses and relays in the box. Make note of any empty positions. If replacing a faulty fuse box, use a fuse puller to remove all fuses and relays, placing them in a labeled container in the exact sequence they were removed. This ensures proper reinstallation if the new fuse box doesn't come pre-populated.
4. 4

   Disconnect wire harness connectors
   Locate all wire harness connectors attached to the back and sides of the fuse box assembly. There are typically 3-5 large multi-pin connectors. Press the locking tabs on each connector and carefully pull straight back to disconnect. Do not twist or rock connectors excessively. Note the orientation and position of each connector. Some connectors may have secondary locks that must be released first.
   ⚠Connector locking tabs are fragile. Use gentle pressure and ensure the lock is fully released before pulling to avoid breaking tabs.
5. 5

   Remove ground strap connection
   Locate the ground strap bolt(s) attached to the fuse box mounting bracket or chassis near the fuse box. Remove the ground strap bolt using a 10mm socket. Inspect the ground contact point for corrosion. If corrosion is present, clean both the strap terminal and mounting surface with a wire brush until bare metal is visible to ensure proper grounding upon reassembly.
   ℹ️Clean ground connections are critical for proper electrical system operation. Ensure all corrosion is removed from contact surfaces.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)
6. 6

   Remove fuse box mounting bolts
   Locate the fuse box mounting bolts securing the assembly to the instrument panel bracket. There are typically 2-3 bolts accessible from the front and side of the fuse box. Remove all mounting bolts using a 10mm socket. Support the fuse box with one hand while removing the final bolt to prevent it from falling.
   ⚠The fuse box assembly is heavier than it appears due to internal components. Support it properly when removing the last mounting bolt.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Remove fuse box assembly
   Carefully maneuver the fuse box out of its mounting location. You may need to rotate or angle the assembly to clear surrounding components and wire harnesses. Feed any attached wire pigtails or grounds through the mounting area as you remove the assembly. Place the old fuse box on a clean work surface.
8. 8

   Transfer fuses and relays to new fuse box
   If the replacement fuse box does not come pre-populated, transfer all fuses and relays from the old unit to the new unit in their exact positions using your reference photos. Ensure each fuse is fully seated in its slot. Verify that all relay orientations match the original configuration, as some relays are directional.
9. 9

   Install new fuse box assembly
   Position the new fuse box assembly into the mounting location, reversing the removal process. Feed any wire pigtails or ground straps through first, then angle the assembly into place. Align the mounting holes with the bracket. Thread in all mounting bolts by hand first to ensure proper alignment, then tighten to specification using a torque wrench.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect ground strap
    Position the ground strap over its mounting point, ensuring the contact surface is clean and free of paint or corrosion. Install the ground strap bolt and tighten to specification. Verify the strap has solid metal-to-metal contact and is not pinched or damaged.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect wire harness connectors
    Reconnect all wire harness connectors to the fuse box in their original positions using your reference photos. Push each connector firmly until you hear or feel a positive click indicating the locking tab has engaged. Tug gently on each connector to verify it is fully locked. Engage any secondary locks if equipped.
12. 12

    Reinstall fuse box cover and trim panels
    Install the fuse box cover by aligning the tabs and pressing firmly until it clicks into place. Reinstall the lower instrument panel trim by reconnecting any electrical connectors first, then positioning the panel and pressing the clips into place. Install the two 8mm screws near the hood release and tighten securely but do not overtighten plastic trim.
13. 13

    Reconnect battery and initialize systems
    Reconnect the negative battery terminal and tighten the battery terminal bolt to specification. Do not overtighten as this can damage the terminal. Turn the ignition to the ON position without starting the engine and verify that all dashboard lights illuminate normally. Start the engine and allow it to idle while monitoring for any warning lights or electrical issues.
    ⚠Battery terminal bolts must be tightened to specification. Overtightening can crack the terminal; undertightening can cause poor electrical connection and starting issues.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all wire harness connectors are fully seated and locked before reconnecting the battery
2. Verify ground strap connections are tight and have clean metal-to-metal contact
3. Double-check that all fuses and relays are in their correct positions per documentation
4. Ensure no wires are pinched between the fuse box and mounting bracket

Verification

• Turn ignition to ON position and verify all dashboard warning lights illuminate and then extinguish normally
• Start engine and verify it runs smoothly without electrical warning lights
• Test all electrical systems: lights (headlights, interior, brake lights), power windows, door locks, radio, climate control, and gauges
• Check for proper operation of all accessories that receive power through the interior fuse box
• Verify no blown fuses or warning lights after test drive
• Use an OBD-II scanner to check for any stored fault codes and clear if necessary
• Confirm all trim panels are secure and properly aligned with no rattles

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