Connections are melting, what could be causing so many electrical problems?

2010 FORD FUSION

179,000 MILES • 1.5L • 4 CYL • 2WD • AUTOMATIC

CHOCOBUNNY77

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I have had to repair both headlight connects twice due to the plastic part melting, the same thing happened to the connector for the blower motor, now my front reading lights will only come on if the door is open, and the horn stopped working. What could be causing so many electrical problems?

Aug 26, 2022 at 7:46 AM

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I would start the engine and hold the RPM at about 1500, then use a voltmeter to check the alternator output which should be about 14.5 volts max. if the voltage is up around 16 or 17 the voltage regulator has gone bad and is over charging the electrical system causing the overheating of components and connectors, here is a guide to help with the test and I have instructions for the alternator replacement below just in case you need it.

https://www.2carpros.com/articles/how-to-check-a-car-alternator

Check out the diagrams (below). Please let us know what you find. We are interested to see what it is.

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Aug 26, 2022 at 10:44 AM