So, my battery light went on the other day. GREAT! an excuse to pickup an Optima yellow top. Got that in, battery light still on. I also noticed a smell of burning electrical equipment. I get a new alternator. Go to put it in. When I disconnect the charge back cable, I notice that the insulation and the ring connector are melted/scorched. I replace it with some new 10 gauge wire and all is fine for now... What would have caused this. THe fuse did not blow and the insulation melted from the alternator back. Any ideas?

The nut that holds the ring clamp/wire to the alternator got loose, caused an unstable connection, created an arc and melted the wiring. Thats my guess.

It happened to me once before. Insured that it was bolted tight and all is well after that.


http://www.dsmregistry.com/detail.php?carid=1185

No, it wasn't an arc... I've driven the car since replacing the cables and alternator. The smell of burning electrical is gone now though. I think the alternator was effed up and overcharging. I'll find out when I take it to the local rebuild shop to turn it into a high output alternator.

Yep, same thing happened to two of my DSMs. The nut on that terminal comes loose, it sits there and arcs itself until the whole post melts down. I could smell it from time to time in the car too until I fixed it.