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Old 12-22-2007, 02:30 PM   #1
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Alternator Problems

Took the Jeep out today (just around town) and noticed that the battery charge was low. Got to the destination and popped the hood...

...found that the #2 cable that runs from the alt to the fuse box was dangling free and (luckily) just hanging against the wheel well plastic shield. Secured the cable w/ tie straps, made it home, and found that it looks like the bolt that the cable attaches to on the alt had burned thru! The plastic shield had melted a good bit, the screw that holds it together was half gone, and the cable itself had obvious signs of some serious heat.

Here are a few pictures of it all:

The 1/2 melted bolt:


The plastic shield and nut:


The cable end:




Very strange...can't think of what might have caused that much heat...


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Old 12-22-2007, 02:44 PM   #2
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Is that a mean green alt? Maybe you needed to get a heavyer wire?

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Old 12-22-2007, 03:04 PM   #3
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If you have a heavy enough wire for the alternator then you may have had a really loose connection which could have caused a massive amount of arcing causeing it to have a meltdown. The nut shows the signs of massive arcing on it.

Or...look at your alternator. The scorch on the sheild above the stud. was your cable bolted tight with the connector running that direction. If so it may have contacted the sheild and cause a dead short causeing massive arcing and a meltdown.
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Old 12-22-2007, 03:23 PM   #4
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Quote:
Originally Posted by Odhinn View Post
If you have a heavy enough wire for the alternator then you may have had a really loose connection which could have caused a massive amount of arcing causeing it to have a meltdown. The nut shows the signs of massive arcing on it.

Or...look at your alternator. The scorch on the sheild above the stud. was your cable bolted tight with the connector running that direction. If so it may have contacted the sheild and cause a dead short causeing massive arcing and a meltdown.
x2
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flowmaster40,hpd30 with aussie locker,currie upper joints,4.88's, lca skids,chromo shafts,vanco brakes,d35 with super 35 and arb locker,re 4.5" springs,currie arms,re front uppers,Re shocks in back,walkerevens shocks up front, Re track bars with currie jj joints,anti rock,ss brake lines,re rear sway bar links,jks 1.25" bl and mml,bfg 35x12.5 km2's,craiger soft 8's,ome steering stabilizer,currie hd steering,rockmen front bumper,emp tank skid,lots more too.
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Old 12-22-2007, 04:45 PM   #5
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Tis a Mean Green 200Amp alt. Am running #2 stranded wire for all backbone battery related cabling. That cable should be stout enough for anything... Have been running the setup for about 2 years so far...

The scorch on the shield that you mention was caused by me. After finding the problem I put the cable back on. It slipped off a bit and hit the shield.

Suppose it is possible that the outside nut was loose...that would mean that it had been arcing back and forth for a while. And thinking about it, this is probably the most likely reason...
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