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So I still have this problem with no solution. I removed the fuse box today. I cleaned all contacts. I was looking at the back of the panel and was curious about something. Some fuses have a wire going to one side of the fuse but not the other. I assumed that a fuse needs a connection on both sides. Seems logical. But if you look at the photo I took, fuse number 3 is empty on both top and bottom, as I would expect since that is not used. #4 is the brake lights and only has a connection on the bottom. I can't find any disconnected wires. This is not the only fuse to have this appearance. I added numbers to ID the fuse locations since it is backwards.
"IMPORTANT !!! You do know that some of the fuse inputs (top connections) are shorted together inside the fuse blocks?? (this varies by year) you need to disassemble these and swap the bus bars for all fuses you need to be separate... THIS IS REALLY REALLY IMPORTANT!!! you can test with a multimeter - not all blocks have this, but all panels have at least some blocks like this...."
Makes sense. Now I'll put the fuse box back in the car. Cross your fingers.
See the pictures later in the thread to understand how this works.
The brake lights, headlight motor, wipers, cruise control, power outlet, windows and sunroof are all controlled by the X-bus - The "X" output of the ignition switch. You said you tested it - but try testing it while activating one of those - say the brakes, it may seem to work (voltage present) when there is no current consumption and fail (voltage drops close to 0v) when there is demand.
19 posts ago I suggested it was the ignition switch - nothing has really changed... I think you need to dig in.