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Old 07-04-2008, 03:51 AM   #1
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Default Alternator Top Wire Burnt...

So I popped the hood of my car today and I saw this!





Car runs fine! I think I know how it happened but I just want to know if I have to worry about it.

For awhile my car battery light and hand brake symbol would stay on and or flicker. I also found out that the positive cable on my battery was loose and I was running my amp along with some HIDs off of it as well. I quickly tightened the nut, but the battery light and hand brake symbol kept coming on and turning off randomly or blinking. I think what the problem was the battery lost charge because now they dont come on any more. Or it might be when I burnt to fuses (same one twice) when I tried to hook up something, but I really dont think thats it haha.

So do i need to worry about that burn make or what?
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Old 07-04-2008, 11:14 AM   #2
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take it off, carefully, and clean it. i'm guessing that happened because it was loose. (since your battery connection was also loose, make sure those are tight!)
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Old 07-04-2008, 11:41 AM   #3
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If it got that hot (probably from a poor connection), the crimp terminal and wires at the end of the cable are all oxidized and burned. You can't fix that with any amount of cleaning so I'd say replace the cable ASAP. It's not long enough to cut and put a new terminal on, and besides that the damage to the wires will go back at least several inches. Of course you also need to clean up the post on the alternator where the cable attaches.
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Old 07-04-2008, 12:44 PM   #4
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This is what happens when a lot of current flows through a bad connection. Muldor is correct about having to replace the wire. You will at least have to cut back the wire to a place it hasn't been damaged by the heat and splice in a new section. A whole new wire would be best though. Also replace the boot cover, it is important. If you work on this yourself be sure to disconnect the ground lead to the battery before working on it as that wire is hot to the battery.

There may also be internal damage to the connection inside the alternator and that should at least be inspected. I suspect the insulator for the stud has been damaged. You may have to replace the alternator. This is the worst connection damage I have seen.
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Old 07-04-2008, 12:56 PM   #5
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I had the same issue, albeit it wasnt as bad as yours.

I cleaned off the terminal and all the problems went away.
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Old 07-04-2008, 02:41 PM   #6
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yeah i just got my car painted and they forgot to tighten the bolts.... gah!! ok so where can I get a new wire at?
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Old 07-04-2008, 03:39 PM   #7
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Nothing special about the wire, you just need a good solid ring terminal to terminate it with. I suggest you cut the wire back enough to get past the damage and splice in a new section using the same gauge wire. Use some heat shrink to cover the splice. Use a butt splice and solder the connection.
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Old 07-04-2008, 04:17 PM   #8
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oky doky will do!!
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Old 07-05-2008, 12:35 PM   #9
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Be sure to replace the boot that covers the stud. You don't want to have it exposed to a possible short to ground if something comes in contact with it and ground.
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Old 07-05-2008, 12:46 PM   #10
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Although splicing is an option if done correctly, given that this is the primary feed from the alternator and can carry up to 75A, the best thing to do is replace the cable completely with a new one. The other end goes to the fuse box under the hood.
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Old 07-05-2008, 03:23 PM   #11
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Being one with the modding bug as the situation allows.
I would say I would have a hard time resisting the desire to cut that alternator wire out and putting in a 0/1 gauge cable to the battery instead
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Old 07-05-2008, 03:26 PM   #12
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Quote:
Originally Posted by Squishy View Post
Being one with the modding bug as the situation allows.
I would say I would have a hard time resisting the desire to cut that alternator wire out and putting in a 0/1 gauge cable to the battery instead
2ga would be more than enough
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Old 07-05-2008, 03:33 PM   #13
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Yeah but I would probably just find a better 0/1 gauge wire deal over a 2 gauge to compensate that
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Old 07-07-2008, 02:38 PM   #14
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well terminal wasnt nearly as Bad as I thought. Just cleaned it and a little bit and it works good! all I need though is a boot, where do you get those at?
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Old 07-07-2008, 05:27 PM   #15
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Quote:
Originally Posted by Uber-Charged View Post
well terminal wasnt nearly as Bad as I thought. Just cleaned it and a little bit and it works good! all I need though is a boot, where do you get those at?
junkyard is best bet. dealership MIGHT sell them, but I doubt it and itll cost a lot more.

as far as I know all EJ series motors have this little thing, aka every impreza legacy forester and tribeca from any year.
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Old 07-07-2008, 05:39 PM   #16
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Try a automotive electrical store or shop. Maybe NAPA also.
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Old 07-07-2008, 06:03 PM   #17
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Do some voltage drop tests between the post on the alternator and the battery positive, make sure there is a good load on the alternator when you do this (turn on the lights, rear defrost, maybe AC). There should not be more than a couple tenths of a volt drop across that cable, if there is you may still have to replace it.
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Old 07-08-2008, 02:22 PM   #18
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Quote:
Do some voltage drop tests between the post on the alternator and the battery positive, make sure there is a good load on the alternator when you do this (turn on the lights, rear defrost, maybe AC). There should not be more than a couple tenths of a volt drop across that cable, if there is you may still have to replace it.
Thats a brilliant Idea, ill do that! I will also try a boot at NAPA
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