Alternator Melted Wire

[pyxis]

I'd appreciate some help diagnosing this problem with my 97 Explorer. First time I started the truck up today, it cranked a little slow but started up. I should of known something was wrong by the way it started up but I decided to ignore it and pay to tow her home later

Later on when I tried starting it up it would make just one click and not do anything else. I took the battery out and had it tested. It turned out ok. I looked over at the alternator and noticed that the wire look a little melted. Looked closer and saw that the whole post had melted off and fused everything together. I pulled the whole post out without any tools and everything just crumbled apart.

I think the wire got loose on the terminal and it arced causing everything to char and eventually melt.

Well I replaced the alternator and tried starting it up but it still makes only one clicking noise and nothing else. I think the alternator might have damaged some other components. I'd like some suggestions on what to check out. Could it have fried the starter? Or maybe the solenoid?

Thanks

 

[ronin2501]

in my experience with the explorer, when the alternator goes it takes the starter with it. I would take the starter out and have it tested.

 

[SoNic67]

Did you CHARGE the battery before trying to start with the new alternator? Because it was empty when you coudn't start before, with the old alternator.
Charge it completelly - a "partial" charged battery could also damage the new alternator.

 

[Blacksheep Josh]

Don't try to jump it either... you need to trickle charge the battery so you don't fry it.

 

[pyxis]

Did you CHARGE the battery before trying to start with the new alternator? Because it was empty when you coudn't start before, with the old alternator.
Charge it completelly - a "partial" charged battery could also damage the new alternator.

I did try to jump start it before I found out the alternator was bad. I really hope that didn't damage the battery in any way. But I haven't tried to charge it since I put in the new alternator.

The guy at Oreillys did say the batter was good after testing it though. Could it still have a low charge?? I'll see about getting a trickle charger tomorrow. Hope those things aren't expensive.

 

[corkey]

check all the battery wires too, the connections could be suspect,,

 

[pyxis]

At the least I'm going to change the wire coming out of the alternator to the battery since it is charred at the alternator end. Anyone know if they sell a kit for those or do I have to cut my own wire and put the terminals on?

 

[SoNic67]

A battery charger should be between 40-60$...
The Explorer battery is pretty impressive so it will take a few good hours to charge at 20A or so.

 

[pyxis]

Would this one work? http://www.autozone.com/autozone/accessories/Schumacher-1-5-Amps-trickle-battery-charger/_/N-2604?counter=3&itemIdentifier=298615_0_0_

I know it's a little low on the amps but it's cheap! Trying not to spend too much moolah here

 

[SoNic67]

That's just for maintenance charge (trickle). It won't charge an empty battery. You need something like this.

 

[pyxis]

Another question...apparently the new starters have connections that are different than the old ones. The original starter had a spade connector on it. And the following connector would slide on:

The new starter has a ring connector:

1) I know the 12 volt wire connection is the same but how do I connect the other wire???

2) Is that second wire supposed to be exposed like that?

Thanks

 

[pyxis]

Well I figured out how to connect the darn wire. New starters are supposed to come with a different connection than the guy at Autozone made. I just went back and made them give me one from a different box. A little crimp, heat shrink and electrical tape and the Explorer starts right up!

I do have one final question though. I'm scared the same thing might happen so I check the alternator output post after every drive! Is it normal for the post to get a little hot after driving? It's not hot enough to melt, and I can keep my finger on it for about 10 seconds. I'm sure it is normal considering all the heat in an engine but I really don't have to money to go through a new alternator and starter again!

Thanks for all the help! This forum has saved me more than a few times

Now to get rid of that squeaking when going over bumps and when stepping out of the vehicle

 

[SoNic67]

The alternator will be hot (like "10 seconds" hot) after a drive anyway. All parts of it.

Squeaking? Check the shocks... At over 100k miles it might be the time for new ones.