For some reason my ground to alternator heated near the tip, that it melted the metal connector and the black housing off. I then use 16 guage copper wires twirled around each other wrapped around with electrical tape and it seems to work fine for about a month or so until that starts to melt off. Anyone have explanation or solution?

to help you narrow it down...

the only reason wires start to melt is because there is too much amperage being sent through them. i have no idea why the stock ground wire would do this though. perhaps somthing is wrong with the alternator?

BTW...our alternator requiers at LEAST an 8 guage ground wire, and running two 16 guage wires leades to a total guage of 13...not enough to account for the load. its no wonder that those melted.


edit!: 5 seconds after posting the above i just realised that there IS no stock ground wire for our alternators, they are grounded through the mounting bolts to the frame. i assume you are talking about the black plastic housing surrounding the wire that goes to the battery (which is a positive wire). look for a short somwhere in that wire, perhaps it has rubbed against the frame and is shorting out. that would explain everything. if you dont get this fixed soon, youll find yourself on the side of the road with a dead alternator and an exploded battery.

Thanks for the heads up. This has been going on for last 3-4 months and I can't really seem to find any exposed area. I've taken the whole engine wire out. Maybe I need to do it again. I do know, however, that at one time some wires were exposed. It was the cam shaft sensor that was shorting out against the head and caused my car to just die and not start at all. One problem after another. My voltometer does show constant 13.3-13.5 which I assume is normal under load.