Alternator wire burnt off - please help

**TunaMike** · 2015/12/15, 07:40 AM

Hello everyone,

I have seen that this topic has been raised in previous threads, however i do not wish to jack someone else's thread so i have started a new thread. A few days ago my batteries stopped charging in my Toyota Fortuner. After a brief investigation i discovered that the wire connecting to my alternator has melted off. I cleaned the melted connection and re-crimped the wire onto the connector and rebolted it to the alternator. 2 days later it burnt off again.

Can anyone please guide me to someone or somewhere that can help me fix this? I am not highly knowledgeable around engines and i'm scared of going to any random auto elec due to all the horror stories i've heard over the years.

my setup it as follows:

2007 Toyota Fortuner 4l v6
National luna dual battery setup
Main battery: 668
Aux battery: 105ah DC

i am currently driving on the aux battery power which by the looks of things won't last see the end of the day.

if any can help, please pm me (or phone - my number is below). I am based in the East Rand area (GP) but will travel as far as PTA to get this sorted urgently (huge thank you in advance to anyone that can help).

Regards
Mike.
24/7: zero 82 9zero6 zero 216

p.s I have emailed Uys from stofpad to ask ask for advice as well as I noticed that his comments on this topic in other threads seems highly knowledgable.

**TunaMike** · 2015/12/15, 07:30 PM

no help or advice or recommendations ?

:_(

**Henris** · 2015/12/15, 07:38 PM

You must not drive without a load on that alternator.

But to replace that lug, should not be a major task.

There are quite a couple of electric buffs here. So just sit tight. They will find you.

**Uys** · 2015/12/16, 06:15 AM

Sorry, Uys has no advice on this one. Never heard off it. But to burn that wire off in 2 days there must be a serious fault! I'll take it to a Auto Electrician or Toyota themselves.

Uys

**Henris** · 2015/12/16, 06:39 AM

Originally Posted by Uys

...........But to burn that wire off in 2 days there must be a serious fault!.........

Not really. A bad connection will do that. Bad connection could just be that it was not tightened down properly. Or the crimping on the lug was not proper.

Either way, it HAS to be attended to.

**duncang** · 2015/12/16, 06:44 AM

Put meter on lug nut and wiggle it whilst revving. Might be loose inside alt body. Also check charge rate.

**PRA** · 2015/12/16, 07:38 AM

Revert to the standard vehicle arrangement by disconnecting the Aux battery system.

After that, if the problem goes away, sort out the Aux battery system.

If the problem persists, find a good auto electrician.