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My alt is melting the conecting wire!! HELP


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So here's the scenario...the other day I hooked up these new head lights I got off E-bay... They were after market and weren't wired correctly. They had two powers ( i guess a high beam ) and a ground. After some testing I thought I had hooked them up properly.

 

Cut to two days later...I'm driving and my stereo and sub start cutting in and out ...then the whole car .. I noticed my battery was at 4...then it dies . So first it was the stereo because it draws the most power, but then it was the whole car. Alright. I get out and look around. The cable coming from the alt ( the big screw down one, not the clip to the excite circut ) was fried. I assumed it was the headlights...so I unplugged them. I then took the ground cable off my sub ( and disconnected the rest of the power to the sub ) and used the ground cable ( becuase its big and fat ) as a power cable for the alt. I basically just ran the alt to the battery..

 

So problem solved...well, for a minute. Now, it's happened again, only I'm confused. I put the stock lights back in, so I don't get it.

 

Even with just a fatty power cable going from the alt to the battery it's still frying the conncetion and causing the battery to fail to charge..

 

Can anyone help? This alternator was a brand new re-furb from Napa about a mounth ago so either the lights being wired wrong originally fried it and now it's got problems...or I missing something bigger.

 

Any suggestions...??!?! PLEASE!!!?!

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I would recommend you get the battery checked out to see if it has a shorted cell. If the battery is ok it sounds like you then may need to replace the alternator with one that has a higher current rating. You may need one that is rated for over 100 amps. You should also repair the burned wiring so the charging circuit is protected.

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Yea..it was sparking when I connected it so that must be the problem. Damn, this alt is like 2 months old. I hope I can find the reciept so I can return it. We will see. Thanks for the help guys, I really apreciate it.

 

I still don't see why though. It started to spark before I ever changed the wire. I assume it's probably terrible to drive it when it's like that?

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