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Old 09-04-2015, 11:25 PM   #1
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HELP!!! Fried wires

I have been having some problems with the whole charging system with my car lately. The car left me stranded last week so i went to check the battery and it turns out it was bad so i got it replaced plus i bought new terminals as well. Also when i was stranded i got it jump started and it would only charge of jiggled the plug that has 3 small wires coming off of it.
Well one week today the batt light turned on again so i pulled over to the side and pushed the cable in again and surprise surprise it started charging again.
On the highway i started to smell something burning so when i got home i checked the trunk thinking it was mu amps or subs but nope. I then popped the hood opened and saw this wire smoking and the lead off the terminal melting. I checked all the cables amd nothing is grounding.
Any help is appreciated
P.s. one of the wires seemed to be tapped when i was going to replaced the plug i noticed that after 2 years of ownership

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Old 09-04-2015, 11:36 PM   #2
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Might have a voltage regulator problem. I'd replace the wires or if there aren't any bare wires then I'd turn it on and turn the lights and rev it and if the lights get brighter and dimmer with the rpms then you have a bad one.
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Old 09-04-2015, 11:48 PM   #3
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Is the voltage regulator in or outside of the alternator. Also i forgot to mention that i didn't smell anything until i turned the bass up but non of the amp wires are touching either or hot

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Old 09-04-2015, 11:50 PM   #4
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Originally Posted by Joser714 View Post
Is the voltage regulator in or outside of the alternator. Also i forgot to mention that i didn't smell anything until i turned the bass up but non of the amp wires are touching either or hot

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Not sure if its internal or external. I'd guess internal tho, you can call any parts store and they can tell you. And that does make a difference how powerful is the amp and how it wired?
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Old 09-04-2015, 11:56 PM   #5
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It's a small 500w rms mono amp. Wired from the batt with a 80 amp fuse about 6 inces after the batt
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Old 09-05-2015, 12:07 AM   #6
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How thick of gauge wire did you use?
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Old 09-05-2015, 12:12 AM   #7
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How thick of gauge wire did you use?
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Old 09-05-2015, 12:15 AM   #8
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4 gauge. According to sonic electronix its true 4 gauge

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Old 09-05-2015, 12:38 AM   #9
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Hmmmm weird. Click image for larger version

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This picture is pretty good in describing why wires melt. So basically you had to much resistance in the wires either due to much power trying to be fed through a wire that is to thin or you wires were corroded causing a higher resistance.

So sense you said it was only after you turn up the subs that makes me think that it was a power surge that fried the wires. Which can still be caused by a voltage regulator so id still get that checked out first then move from there.
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Old 09-05-2015, 01:12 AM   #10
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I am thanks. I did a google and i think on the v6 it was external and on the v8s it was internal but I'll see what oreilys and pep boys say

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Old 09-05-2015, 01:18 PM   #11
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I think that this may have been caused by the faulty connector on the alternator. The question is, did the amplifier cause the connector to get hot? Or was it just a bad connection at the alternator which caused the overheating?

Have the alternator tested and replace the connector to the alternator.
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Old 09-05-2015, 02:40 PM   #12
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I think that this may have been caused by the faulty connector on the alternator. The question is, did the amplifier cause the connector to get hot? Or was it just a bad connection at the alternator which caused the overheating?

Have the alternator tested and replace the connector to the alternator.
I'm getting it bench tested and I've had that same amp with the same subs in that car for a little over 2 years though. I also don't think the sell that connector on its own 😭 i really don't want to pay another 200 for an alternator

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Old 09-05-2015, 03:08 PM   #13
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I'm getting it bench tested and I've had that same amp with the same subs in that car for a little over 2 years though. I also don't think the sell that connector on its own 😭 i really don't want to pay another 200 for an alternator

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They might have that connector at the auto parts store. I had to replace one on my truck a couple of years ago. You will have to solder it on to the factory wiring harness.
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Old 09-05-2015, 07:26 PM   #14
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They might have that connector at the auto parts store. I had to replace one on my truck a couple of years ago. You will have to solder it on to the factory wiring harness.
any good parts house will have the pig tail,you may have to replace the regulator as this is where the plug plugs into. sounds like it may be bad is what started the whole mess.pulling to many amps through the plug will melt the plastic connector then it shorts the wires and burns them.if you need altenator go to lkq,you have to take it off but save bunch's of dollars.take a pair of dikes and get the pigtail at the same time.
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Old 09-05-2015, 09:45 PM   #15
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any good parts house will have the pig tail,you may have to replace the regulator as this is where the plug plugs into. sounds like it may be bad is what started the whole mess.pulling to many amps through the plug will melt the plastic connector then it shorts the wires and burns them.if you need altenator go to lkq,you have to take it off but save bunch's of dollars.take a pair of dikes and get the pigtail at the same time.
I went to autozone with no luck but will try oreilys, pep boys or napa. The alt is good acording to their tests but I'll take it with a grain of salt
I do have the pigtail but not the regulator or the orange thing that melted
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Old 09-06-2015, 01:53 PM   #16
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I have been having some problems with the whole charging system with my car lately. The car left me stranded last week so i went to check the battery and it turns out it was bad so i got it replaced plus i bought new terminals as well. Also when i was stranded i got it jump started and it would only charge of jiggled the plug that has 3 small wires coming off of it.
Well one week today the batt light turned on again so i pulled over to the side and pushed the cable in again and surprise surprise it started charging again.
On the highway i started to smell something burning so when i got home i checked the trunk thinking it was mu amps or subs but nope. I then popped the hood opened and saw this wire smoking and the lead off the terminal melting. I checked all the cables amd nothing is grounding.
Any help is appreciated
P.s. one of the wires seemed to be tapped when i was going to replaced the plug i noticed that after 2 years of ownership

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what year/engine is this mustang
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Old 09-06-2015, 03:04 PM   #17
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what year/engine is this mustang
2003 V6 3.8 with about 147k miles
Alternator and battery are not oem

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Old 09-06-2015, 06:27 PM   #18
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Why the hell would someone do this

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Old 09-06-2015, 10:22 PM   #19
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Anyways i just got a new alternator, pig tail connector, idler pulley and tensioner since it squeaked on start up.

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Old 09-07-2015, 12:59 AM   #20
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Because they are lazy... And is the pig tail long enough to go before the all jacked up wiring?
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Old 09-07-2015, 02:25 AM   #21
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Because they are lazy... And is the pig tail long enough to go before the all jacked up wiring?
Yea it was. I went as far back as i could. I suck at soldering but I'm sure it was better than there twisting plus i used shrink tube and finished it with electrical tape so hopefully it'll last

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