If possible, I'd love to see a photo of the device you found.
That connection can be tested the same way, with the two meter probes just a fraction of an inch apart, with one on each side of the bad connection. That's how we find bad connections in starter circuits, by moving from one connection to the next until we find the one with any voltage higher than 0.0 volts. But here again, and especially in the high-current starter circuit, that undesirable voltage will only show up when the circuit is trying to operate. That means using a helper to turn the ignition switch to "crank", or by using a remote starter switch.
On most models, large fuses are for the generator's output circuit. They don't involve any other circuits from working normally. Here, however, in these diagrams, you are correct that this fuse does indeed feed the Rear Fuse Box. The first one shows the Rear Fuse Box, and at the top is the 125-amp fuse from the Under-Hood Fuse Box. In the second one, I just expanded it to make it easier to see the fuse at the top.
Here's the way I interpret this part of the diagram. At the very top in the square box, it says, "B+". That goes back to the early 1900s in the first days of portable radio. Tubes needed three voltages to operate. The "A" battery ran the filaments in the tubes. The "C" battery ran other circuitry. The "B" battery provided the high voltage used in the "plate" circuits for the tubes. (You won't be tested on this later), but the "B+" designation has stuck around all this time to denote the power source, in this case, the 12 volts coming directly from the battery. Once the current passes through some other part of the circuit, other than fuses, it is no longer called "B+".
The reason this is important is right above the fuse you see, "B+ Bus" going to the left. That means it is a buss bar that all the other fuses are connected to in that square box, which is the Under-Hood Fuse Box. Most importantly, that circuit taps off before the 125-amp fuse, so nothing there is protected by that large fuse.
Below that fuse, nothing is shown as tapping off inside the Under-Hood Fuse Box or after it, other than the red wire going to the Rear Fuse Box. If the 125-amp fuse was protecting something else not related to this diagram, it would have been noted the same way as that "B+ Bus" designation did. To say that a different way, if you remove the 125-amp fuse or if it has a bad connection, everything in the Rear Fuse Box would be dead, but only the circuits coming from that fuse box. Everything coming from a fuse in the Under-Hood Fuse Box would still operate normally.
To add one more point of confusion, when the Rear Fuse Box is dead, some circuits in the Under-Hood Fuse Box will also appear to be dead, but this can be misleading. I didn't research this to verify it, but it is very common in most models to have a fuse inside the vehicle feeding one of the three or four parts of the ignition switch, including the part that turns on the low-current side of the starter relay. That relay switches on the medium-current side of the starter solenoid, (bolted onto the starter motor). That medium-current part of the system is fused in the Under-Hood Fuse Box. There's actually nothing wrong with the medium-current part of the system. It just doesn't turn on because the low-current part is not working.
This is why we often sound repetitive when we ask people for additional observations or information, such as, "do you hear a relay click", "are any other lights also not working", and things like that.
I agree, it sounds like what you found is not factory. I don't recall ever seeing a wire attached with a set screw. It sounds like that is something that was added on to allow other wires to be attached, such as perhaps for a snow plow or roof lights. Regardless, it sounds like it's wired correctly. This would be a much better alternative to the way a lot of people add wires. That is to bolt them right to the battery cable. By far the worst example, and never acceptable, is to attach a ring terminal under the cable on a GM side-post battery. Those cables make their connections where the ring of lead in the cable end contacts the ring around the threaded hole on the battery. Sticking a ring terminal in there detracts from the nice solid connection that is formed when squeezing the two soft lead surfaces together. A future intermittent connection is guaranteed to develop, and that very little additional resistance introduced means a huge deal to the starter circuit that requires very high current.
Just as bad is trying to add a wire under the head of the bolt that holds the cable to the battery. That bolt is not connected electrically to the cable. It does get 12 volts through its threads, but those threads are not designed for current flow or for excessive tightening. Added-on wires will crush over time resulting in loose connections and often some arcing that burns the lead rings away. Next comes repeated tightening, often to the point the threaded hole strips out. Once the terminals have arced away, there will always be a less than perfect connection no matter how much the cables are tightened.
With top-post batteries, we used to occasionally see where someone stuck a wire in between the post and the cable clamp. The posts are that big in diameter because that is what's needed to allow up to 300 amps to flow to get a V-8 starter going. (That does drop down a lot later, but that's a story for another day). When wires are stuffed in between the post and cable clamp, a lot of that contact area is eliminated, often the point what is there burns away from having to handle all the starter current. It's common to find you can just lift the cable off without loosening the bolt.
From what I'm visualizing, it sounds like the part that was added on is not in the high-current starter circuit and it was the best way to add on other wires. Be aware too, at least back in the '80s and '90s, GM was real good about including unused terminals in their fuse boxes for just such add-ons. Their fuse boxes down in front of the brake pedal usually had a single unused terminal marked "Batt", meaning it had 12 volts all the time, and another one marked, "ACC", meaning it had 12 volts only when the ignition switch was in "run" or "accessory".
Besides those spare terminals provided, there are a number of other way people use to add wires, and most are not acceptable for a quality job. Worst is sticking a pigtail terminal alongside the end of a glass fuse or alongside a spade-type fuse. Those used to be common when car phones first started showing up. Those terminals spread the terminals in the fuse box. Later, when the car is traded in and those accessories are removed, the fuse terminal is loose in the fuse box and causes intermittent operation. The most elusive problem is when the affected circuit appears to keep on working, but the added resistance between the terminals causes heat to be generated, and that leads to intermittent blowing of that fuse. Fuses work by their elements getting too hot and melting. The real solution is to sand the fuse box terminals clean, then squeeze them to make tighter contact. Some people used to "solve" this by installing a larger fuse, but that didn't fix anything.
So much for today's story hour. I'm very happy you solved this problem.
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Saturday, February 25th, 2023 AT 4:10 PM