http://www2.zoto.com/ilikeitsideways/img/680x680x2/f7276f09f9b35c3b81f26db7a789ac2d.jpg

This is my problem. The lead to the alternator was glowing red, so I disconnected the battery, and I've traced the wires all the way back to the relay box, and checked the fuses. No fuses are blown. The wires look fine all the way back to the box. No signs of arcing.
I had the alternator checked, and everything checked out ok. Correct voltage, the regulator is ok, etc etc.

So any ideas on where else to look? I checked other grounds and traced wires back to those grounds.
I hate wiring, and I've never been good with figuring electrical problems out. Any help would absolutely rock. I hope it's something stupid.

This problem seemed to have developed overnight. One day it was fine. The next, it started glowing (and melting)

I checked other grounds and traced wires back to those grounds.


that isn't a ground, that is the positive terminal. (alternators ground through their mounting points generally)

take a multimeter and test from the alt end of that cable to the battery positive terminal. should have zero volts. now check from the end to the negative terminal, should hopefully have 12 volts. if either of those isn't correct, the cable probably rubbed through somewhere and is shorting to ground.

that isn't a ground, that is the positive terminal. (alternators ground through their mounting points generally)

take a multimeter and test from the alt end of that cable to the battery positive terminal. should have zero volts. now check from the end to the negative terminal, should hopefully have 12 volts. if either of those isn't correct, the cable probably rubbed through somewhere and is shorting to ground.

I know it's not a ground, I was stating that I checked grounds to try to pinpoint the problem :)
I'll check with the multimeter, that should hopefully locate the problem. Thanks for the advice :)

I know it's not a ground, I was stating that I checked grounds to try to pinpoint the problem :)
I'll check with the multimeter, that should hopefully locate the problem. Thanks for the advice :)

oops, sorry misread!

but the multimeter test still should work as is. As you described it I highly suspect the cable from the battery to alt has rubbed through somewhere.

Right on, I'm about to go check it now. Thanks for pointing me in the right direction, that is helpful :D

Edit: Both of those checked out ok.

.......

Have you done anything to the car recently? Is the wire only burnt at the lead or is the wire damaged throughout?

I suspect that this problem was just caused by a bad connection to the alternator stud bolt, and not a short. A bad connection there will really heat up due to the high current running through the connection. From the looks of the picture you should at least repair the alternator main output connector. You have to just replace the alternator. Cut the burned wire lead back to a place that hasn't been damaged and splice in a new section and terminate the end with a good quality ring terminal. You will be back on the road again.