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Old 09-11-2010, 12:43 PM   #1
Andirkanod
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Member#: 170283
Join Date: Jan 2008
Chapter/Region: NWIC
Location: Eugene
Default BIG! wiring problem

TIA for any info or help with my problem, it is appreciated!

some car info:
2003 WRB WRX
2nd owner
no issues at all whatsoever

About 2 months ago I did a front end swap and put on an 04-05 sti front end. I wired the headlights knowing that the grounding wire and headlight wire could possibly melt. Well they melted because the wire was circled around itself and touching in 3 different places making the wire super hot, therefore causing the melt. I could see a little smoke coming out of my dash so i pulled over immediately to see what the issue was. A small fire on my battery! the wire had melted into my battery! I quickly pulled the wires apart while the car was will on. Bad idea! I'm pretty sure when i did that I shorted a lot of fuses. The car is still driveable but the speedometer is out, my windows dont work, turn signals, horn, headlights. But the stereo works the rpm's, work, brake lights and the clock works. So I'm hoping that I will need to change out the fuse's for all of those things and I'll need to rewire the headlight and this time make sure they cant melt. Thank you!

**I just want to make sure I'm correct in that changing the fuses it will make the issue go away. well everything but the headlights is my main concern right now.
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Old 09-11-2010, 02:27 PM   #2
Big-E
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2006 WRX Sedan SGM
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Quote:
Originally Posted by Andirkanod View Post
About 2 months ago I did a front end swap and put on an 04-05 sti front end. I wired the headlights knowing that the grounding wire and headlight wire could possibly melt.
If you knew, then why would you go ahead with the modification?

Quote:
Originally Posted by Andirkanod View Post
Well they melted because the wire was circled around itself and touching in 3 different places making the wire super hot, therefore causing the melt. I could see a little smoke coming out of my dash so i pulled over immediately to see what the issue was.
You may have in fact melted wires behind the dash, burned out fuses and relays, as well as for having caused damage to the instrument cluster and so-on.

Quote:
Originally Posted by Andirkanod View Post
A small fire on my battery! the wire had melted into my battery! I quickly pulled the wires apart while the car was still on. Bad idea! I'm pretty sure when i did that I shorted a lot of fuses.
Is the battery still sealed or is there now a hole in it or are any of the battery cables melted?

Quote:
Originally Posted by Andirkanod View Post
The car is still driveable but the speedometer is out, my windows dont work, turn signals, horn, headlights. But the stereo works the rpm's, work, brake lights and the clock works.
See second response above.

Quote:
Originally Posted by Andirkanod View Post
So I'm hoping that I will need to change out the fuses for all of those things...
At a minimum you can check for blown-out fuses and replace them. You need to realize that there is a main fuse and relay box next to the battery under the hood, as well as for the fuse and relay board behind the driver's lower dash.

Quote:
Originally Posted by Andirkanod View Post
...and I'll need to rewire the headlight and this time make sure they cant melt.
I'm curious as to how you wired the headlights in the first place so that you don't commit yourself to a repeat performance.[/quote]

Quote:
Originally Posted by Andirkanod View Post
**I just want to make sure I'm correct in that changing the fuses it will make the issue go away. well everything but the headlights is my main concern right now.
At a minimum you can try and find-out, but with electrical problems as you have described end up being much, much more involved than just this.

Good luck!
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