Alternator wire from alternator to starter smoking hot broke

Tiny
TINMAN1001
  • MEMBER
  • 2012 CHEVROLET MALIBU
  • 2.4L
  • AUTOMATIC
  • 80,000 MILES
Installed a remanufactured alternator. Wire between alternator to starter started to smoked and broke. Used a piece of wire and added a splice to replace broken wire. The replacement wire was just twisted together and taped with electrical tape. Alternator appears to be charging the battery at approximately 13.5 volts but had to shut it down because wire between alternator and starter was starting to smoke. Also the end of the battery cables were being changed and they crossed touch the cable to the negative and positive battery posts and caused a spark before connecting the battery. Could this caused the wire between alt and starter to get very hot? Or something with alternator? Does the wire between the alternator and starter have a fuse? I didn't see anything that looked like a fuse.
thanks
Saturday, June 26th, 2021 AT 11:26 AM

1 Reply

Tiny
94 TRANSAM
  • MECHANIC
  • 680 POSTS
The charge wire from the battery to the alternator is a fusible link. The wire is a fuse. If it gets overloaded the wire burns in half. When you shorted the cable you probably partially cooked the wire so now there isn't enough wire to carry the load and is over heating now. You can goto any parts store and they can look up the rating for a new link and sell it to you. Then simply replace the old wire with a new one and add the new link to it. This is caused by a bad battery so please replace it. Let us know if you need any more help.

Rich
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Saturday, June 26th, 2021 AT 11:49 AM

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