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Add circuits directly to Aux Junction Box using OEM terminals


Don Ridley
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The Auxiliary Junction Box (AJB) is located in the access panel in the right rear of the van. The AJB has a lot of spare fuse slots for switched and constant power. The AJB is made by Lear in the UK or EU and finding a US source for the terminals has been a challenge. After much trial and error and with the help of DonShockley, here is a local source for the terminals needed to properly add circuits to the AJB:

 http://www.mouser.com/ProductDetail/TE-Connectivity-AMP/1-968857-3-CUT-STRIP/?qs=sGAEpiMZZMs7eK6h2EBtKpfjTZYxfnESgPEJGoSWVDw%3D

http://www.mouser.com/ProductDetail/TE-Connectivity/1-968859-3/?qs=%2Fha2pyFaduhqy3aI3kZvUXP11VT0ejBFP6KL61KptWcoM%2bOzVMsngg%3D%3D

 

The 968857-3 terminals are for #14-10AWG wire. The 968859-3 is for #10AWG and larger. You will need a crimping tool but they can be found for around $15. The only problem with this solution is you need to buy 100pcs for most terminal sizes. I have all the terminals I will need but maybe others can share the costs. Adding circuits properly and safely is well worth the cost and effort. No unsightly splices or piggy-back solutions!

The AJB is fed by a 70 amp fuse so you can safely add a 20 or 30 amp circuit and numerous smaller ones for Led lights or other low power accessories. The AJB has two types of spare fuse slots: one has single-sided contact with the power buss bar and other has double-sided contact. Use the double sided ones for high amperage circuits. You can see the copper contacts from the front of the AJB.

AMP_Lear terminal spec.pdf

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A couple of things that I want to install on my imaginary Transit Connect are a cell phone signal booster, and a power inverter.  A quick look at where the junction box is located shows me that there is plenty of space to work with.  I can also easily access the 12 volt fused wire for the OEM power supply.  I can see that the ground is attached to the body right behind the base for the seat belt.  The base of the junction box has a ton of wires fed into it, and there are only a couple of fuses and relays installed in that junction box.  So the logical presumption is that a lot of power is being fed into that junction box, that is not being used.  Now, how to gain access to all that power.  That junction box could potentially supply power to a lot of aftermarket mods like warning lights, A pillar mounted spotlights, Streamlight charger bank, entertainment system, a disco ball, led lamps, air compressor for an airbagged suspension, air compressor for air tools, air compressor for air, and electronic marital aids.  

 

BBJ or Don Ridley, 

Please post pics and share any relevant instructions so that those of us who are less than knowledgeable have a template to follow.  Anything to look out for or be mindful of?  Should we disconnect the vehicle battery prior to starting any projects?  A step by step would be helpful.  Since I am only driving an imaginary van.

 

 

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https://smile.amazon.com/Automotive-Connectors-MCP2-BU-KONT-piece/dp/B0137JUUQ4/ref=sr_1_1?ie=UTF8&qid=1474949759&sr=8-1&keywords=1-968859-3

Automotive Connectors MCP2,8 BU-KONT EDS

Automotive Connectors MCP2,8 BU-KONT EDS

Available in multiple versions


Price: $0.44 - $36.40 
 
Product Specifications
Brand Name TE Connectivity
Part Number 1-968859-3
UNSPSC Code 26121600

 
 
 
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https://smile.amazon.com/TE-CONNECTIVITY-AMP-1-968857-3-Contact/dp/B0167ZFHH2/ref=sr_1_1?ie=UTF8&qid=1474949749&sr=8-1&keywords=1-968857-3

21P3Yu%2BT8vL.jpg

TE CONNECTIVITY / AMP 1-968857-3 Contact, MCP 2.8 Series, Socket, 17 AWG, 13 AWG, Crimp, Copper Nickel Silicon

Available in multiple versions


Price: $0.36 - $65.80 
 
Product Specifications
Brand Name TE Connectivity / AMP
Part Number 1-968857-3
UNSPSC Code 32000000

 
 
 
Currently showing 1-5 of 5
ASIN  Size Price  
 In Stock Only
All    
Currently showing 1-5 of 5
B0167ZFIGC 1 pack
$0.36
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B0167ZFJEI 10 pack
$6.58
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B0167ZFM7C 50 pack
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Fifty, 

BBJ will have an inexhaustible supply soon but it is a nice surprise to see them available on Amazon. I thought once I found the right part numbers they should be easy to find. The terminals simply plug into the back of the fuse block. Add a fuse up front and you have an OEM type circuit. You need a crimp tool like this. Shop around for a better deal.

https://www.amazon.com/gp/aw/d/B00SZL59NY/ref=pd_aw_sbs_60_of_12?ie=UTF8&psc=1&refRID=ZT3T3N4DQNBJDMN6RP87

I am waiting for some audio components before I start my wiring project. 

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On 9/27/2016 at 9:20 AM, Don Ridley said:

The terminals simply plug into the back of the fuse block. Add a fuse up front and you have an OEM type circuit.

 

 

Okay, so that means that I would have to remove the fuse block, add the terminal, then reinstall the fuse block.  It looks like it's simple enough to remove the screws, then lift up and out.  

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On 9/27/2016 at 9:20 AM, Don Ridley said:

Thanks Don,

 

........and since I am an amatuer, I had to search online to learn what to do.  This should help someone like me, who has never done it before.

 

 

 

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Yes, the last tool will work. Removing the fuse block is easy. Insert the terminal crimped onto a length of wire paying attention to the direction of the contact slot so a fuse can be inserted. This is almost as easy as changing a light bulb.

Use the smallest amp fuse you need. 5 amp works for all LED lights. 20 and 30 amp are only for large loads.

I use 14awg wire minimum for everything, plus I have a big spool of it (MTW type, not THHN).

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On 9/25/2016 at 8:47 AM, Don Ridley said:

The Auxiliary Junction Box (AJB) is...

 

 

THANKS for posting this. Just ordered 10 from newark.com, neither of the amazon retailers seemed to realize we've been a State since 1959 and USPS etc.. services the tundra just like everywhere else in the colonies ;).

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Everything is focused on The Lower 48.  Same story in Hawaii.  Everything is focused on The MainLand.  AK & HI get the short end of the stick when it comes to shipping.  And shipping is the primary reason why everything is so expensive.  What are you paying for a gallon of milk these days?

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24 minutes ago, Fifty150 said:

Everything is focused on The Lower 48.  Same story in Hawaii.  Everything is focused on The MainLand.  AK & HI get the short end of the stick when it comes to shipping.  And shipping is the primary reason why everything is so expensive.  What are you paying for a gallon of milk these days?

Actually, I couldn't tell you what a gallon of milk is, haven't had it in many years, do the soy/cashew/almond stuff. Prices aren't actually terrible around Anchorage, with regular flights, ferries, and even trucking from the lower 48. Fruit is certainly not too fresh by the time it arrives! It's just funny how many places will say "we don't ship international" or think they have to contract with NASA to get anything here when, as long as it isn't hazmat, we have all the same options as anywhere else. Other than the bush, where that is not the case, I can imagine HI gets a shorter stick than us being the trucks wouldn't get too far leaving CA.  

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On The Islands, everything has to be imported.  As you can well imagine, anything locally produced is scarce, in high demand, and often cost more than something shipped or flown over.  Even the worst coffee from some Central American "banana republic" is expensive.  But the local Kona will still demand a higher price point than what came off the back of Juan Valdez's mule.  Everything is a commodity.  Even wives.  But female companionship is another conversation entirely.  That's why I'm back on The MainLand, and driving a Panty Wagon.  

Edited by Fifty150
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http://www.edmunds.com/about/press/hawaii-and-california-most-expensive-states-to-own-a-car-while-new-hampshire-and-south-dakota-least-expensive-according-to-edmundscom.html

 

 

SANTA MONICA, Calif. — May 4, 2010 — A study by Edmunds.com, the premier resource for automotive information, shows that owning a vehicle in Alaska, California or Hawaii over a five-year period is about $10,000 more expensive than owning the same vehicle in New Hampshire, South Dakota or South Carolina for the same duration.

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Puerto Rico, Guam, Micronesia, American Samoa, Virgin Islands, Marianas.....none of them are states.  Actually, neither is The District of Columbia, as in Washington D.C.  US Territory just means that we are jerks who tell them what to do.  A bully.  Like a stepson who you don't care about, but you still give him an allowance.  

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