HELP*** 12V from Alternator to Solenoid/Battery getting Sizzling HOT [SOLVED]

[Tommy]

I need some advice, as I'm remedial with electrical.

My '90 SSP apparently has had this issue for a while but I just truly noticed it.

It has a 130amp alternator (previous owner upgrade or SSP upgrade?). The two wires (blk/org and ylw/wht) leading to the solenoid are fine leading out of the alternator, and under battery tray area. Now just after the stock battery tray area, leading into the solenoid, the wire gets sizzling hot! and melting the insulation.

I had seen the bare wire at one point, so I wrapped it with electrical tape to cover it, then later sealed it with shrink tubing.

Well, today while checking out the car to prep for tomorrows runs, I noticed the wire "smoking". Its getting too hot to even touch.

I had my alternator checked out and the voltage was spiking from 14.4 to 16+, so I bought a new one. Connected it, and same story ....wire getting HOT.


I'm unexperienced with electrical....what should I be looking in to?

[Edgar]

Hmm that's kinda odd. Check for a short somewhere maybe?

[Tommy]

Hmm that's kinda odd. Check for a short somewhere maybe?



Those wires go directly from the alternator, combine into one and go into the solenoid positive (12V+) battery side to recharge the battery. There are no other circuits or grounds on that harness.


Soooo, short....not likely.

[Tommy]

I got a few responses on another forum. Seems like the two wires leading into one are not enough to handle the 130amp alternator. These foxes originally didn't come with such a high amp alternator so the stock wiring doesn't handle it well. It's getting hot because of the resistance going through it

[50enzo]

so how you gona fix it?

[Powershift03]

Tommy, the SSP Mustangs came with 130 amp alts from Ford. Sounds like you have an obvious resistance issue. Either the wiring isn't big enough to handle it, or there is high resistance at the starter. The Alt is trying to overcome the resistance, which builds up heat in the wire, thus creating more resistance, etc.

[Jose]

Tom

Did you get it fixed ?

[Tommy]

I bought a new alternator since my old one was spiking up to 16 volts, then dropping to 10.

I wired a 4gauge from the alternator to the 4gauge leading to the battery. Problem is that the alternator is now reading -0-.


I just did a little more research and found that there is a voltage sensor wire that I may have cut and not re-connected. I'm sitting at the Irwindale parking lot right now so I'll have to work on it tonight.

[Tommy]

ALL FIXED!!!



Ready to waste my ET Streets!