alternator red wire super hot melted - Ford Powerstroke Diesel Forum
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Old 03-21-2014, 08:11 AM
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alternator red wire super hot melted

So i had the truck running and was just checking the fluids when i noticed little puffs of smoke coming from the back of the alternator where the red wire connects. then i noticed the rubber that protects the outside of the wire had been melted. so i disconnected both batteries to undo that wire and then the nut and top half of the screw broke off, i guess from the extreme heat. but the screw was actually melted inside of that nut. now i'm guessing a new alternator is en route but what caused that in the first place.

could my sub do that? i have had the sub in the truck since day one and have since done the erg delete and replaced the oil cooler and noticed nothing back there.

Last edited by xander40; 03-21-2014 at 08:15 AM.
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Old 03-21-2014, 08:39 AM
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i had my headstuds done at ford and when i picked it up I smelled electrical

i turned off all my electronics and it went away but when I got off the freeway and popped the hood I found my boot melted at the alt and the nut loose

they left the nut loose which in turn gives the alternator the signal to output full load

the bad connection causes heat mine was an easy fix DC power sent ME a new connector and Ford apologized same alt has been fine for 2 more years

I imagine yours was loose also but check the fusable ink in that same wire if it's open it could cause issues
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Old 03-21-2014, 08:40 AM
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what about how that screw that holds the red wire on breaking off, would i not need to get another one becaue that screw is not coming out of there
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Old 03-21-2014, 08:52 AM
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i think your alt is done I got lucky the one i had used an adapter so the adapter fried at the nut yours doesn't use the adapter so the unit is fried IMHO
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Old 03-21-2014, 09:00 AM
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DC 185 alt is on sale this week. Not that I have been watching them or anything.
https://www.dcpowerinc.com/fit/Ford~...7-185-oem.html
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