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Check your alternator!
The connection between the battery wire and the threaded stud of my alternator was oxidized, but otherwise tight. The poor electrical contact caused the stud to overheat which melted the plastic innards of the alternator. The symptoms were a battery idiot light on for about 2 minutes and then off. I checked the connections after driving to work the next day, and discovered that the battery wire was hot to the touch. The system voltage, charge rate, amp draw, and condition of both batteries was found to be normal. The alternator was pulled, and the oxidized connection was found along with a crispy stud boot and partialy melted insulator around the stud. The alternator passed a computerized test, but the melted condition of the innards was discovered apon teardown. With new guts and clean connections, its back to normal. The moral/s? Battery wire should not be hot to the touch soon after start-up. Since the sleeve of the battery wire boot faces up, I suspect that water ran down the wire into the boot and collected around the stud. Or, the ring connector of the wiring harness was already oxidized when it was assembled to the alternator. [img]graemlins/shrug.gif[/img]
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7.3 Excursion, it's a diesel thing.
Chicago MOB member.
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