I recently solved my non-start issue with a replacement cabin fuse box. Works fantastic and just last week polished off a 1K-mile road trip without a single issue. Runs like new! BUT, I just started noticing a random HDC light that pops on with the Nanocom code showing a brake light relay short, which after a quick google led me to your post @nashvegas Thanks so much for posting that btw, its exactly what I'm experiencing.

It's intermittent, it'll be on for a bit. I'll turn off the truck, wait, restart, and it'll be off for the rest of the day or something. Odd right?

So now it looks like the fuse box I received has an issue, so ordered another off eBay in hopes that'll be the final fix.

That being said - I'll gladly spend a lot of money if a brand new one were available. Any idea is they still are? I found a NOS fuse box on eBay but was for an 03-04 unfortunately. I hate that I feel the need to start hoarding interior fuse boxes if I want this Disco to last a few more decades.

 

I'm currently working on a refresh of my 01 and came across this site I had saved along the way. Turners Garage If you have the original box it might be worthwhile to send it out and get it rebuilt. If your looking to keep your rig for the long haul having piece of mind is always better especially seeing what you have overcome. Another option is to contact Will Tillery. Everything electrical I have purchased from him over the years comes with a 1-2yr warranty. He always personally tests his items before sending out.

 

Hero! Will do.

 

Solved. Yes, was indeed being caused by that relay you mentioned @nashvegas Replacing the fuse box was the solution. You can see a little bit of corrosion inside near that relay AND the relay itself looks like it took an impact or something.

 

Fascinating and glad my post helped! It does look like the relay took an impact w/ that crack.

The fuse boxes are definitely not available new. BTDT.

It does stink that this HDC/Brake relay is not removable. I’m sure someone could figure out how to unsolder them eventually when we start getting desperate for parts. In certain cases, I’d surmise that the actual relay is good but the tracing / mounting surface / circuits to / from are correded and the issue.

I try to pull fuseboxes out of non-leaking D2’s whenever I see them in junkyards. If the truck is wet inside, I skip even looking at it. It’s always corroded.

Sadly, I only have one spare right now though for 99-02 that I’m hanging onto.

My sense is all it takes is one water ingress into the fusebox, and things go haywire a few years later...