Have just noticed that the plastic surrounding the leftmost fusable link (110 amps) in the distribution block above the battery is melting on my Octavia 1.6.

The dealers just replaced the complete distribution box on a coworkers Octavia for the same fault and I decided to go and check mine... and the plastic on mine is melting too!

I sanded the surfaces clean, cleaned them with contact cleaner and retorqued the nuts, so I'm hoping it will not get worse.

I'd advise everyone to go and check the same on their Octavia.

We get this problem regularly on our SDI Octavias, once they've done that bit, the battery cable itself will start melting, then when thats replaced the other bit will melt again, repeat add infinitum!

Obviously a serious design flaw somewhere!

(it should be noted however that our cars have a fair amount of electrical equipment in them, drawing more power than usual)

Ford Galaxys have a similar problem on the PD engined ones

caused simply by a bad connection. as you say probably a design flaw somewhere.

I'd insist on a proper solution. Not great to have that kinda energy going through dodgy connections/cables. Aren't electrical faults meant to be the domain of the French cars :P

Thing I dont quite get though is why replacing cable + melted bits at the same time wouldn't sort it? If it doesnt sort it the cable is not big enoughand/or the clips are cr*p.