Electrical problem from hell

[Jimmy Jr.]

First off, I have a new alternator and a new battery so those aren't the problems, corrosion on the terminals isn't the problem either. I've been through six alternators and Napa isn't going to give me anymore under warranty.

When I turn anything electrical on e.g. lights, fans, or when i depress the brake the volts take a huge dive. Sometimes the car runs like shit and sometimes the car runs like new. I drove 3 hours on sunday and a mile from my house the car died at a stop sign and wouldn't start. I popped the clutch and the car ran like new. Could it be a relay? All the wires by my alternator are burnt to a crisp from the dp coming loose. Do I have to get a whole new harness just to replace them? WTF is up with my car?

 

[zephyr_8]

You're going to need to do a voltage drop test across those wires. If it loses alot of voltage then you'll need to replace them. If they looked fried they probably are you're problem.

 

[Jimmy Jr.]

can i simply cut those wires and solder in new ones?

 

[GTM]

...
I've been through six alternators and Napa isn't going to give me anymore under warranty.

When I turn anything electrical on e.g. lights, fans, or when i depress the brake the volts take a huge dive. Sometimes the car runs like shit and sometimes the car runs like new. I drove 3 hours on sunday and a mile from my house the car died at a stop sign and wouldn't start. I popped the clutch and the car ran like new. Could it be a relay? All the wires by my alternator are burnt to a crisp from the dp coming loose. Do I have to get a whole new harness just to replace them? WTF is up with my car?

Two alternators should tell you there is a problem, six should tell you maybe it's time to fire the mechanic and get a real one.

It sounds as if the B+ lead from the alternator has shorted in the loom. You can temp make your own B+ using #8-10 gage wire after disconnecting both end of the existing feed. The other 2-3 #14-16 wires would have completely burned up though they too may be damaged and need replacing.

You should check all engine and body grounds for it's possible they are loose allowing for huge surges as they arc and overload the alternator. Certainly other large current carrying wires such as headlights, heater blower, ignition circuit, relays must be inspected. You need to buy proper electrical test equipment tools including short finders and understand how to use them in conjunction with a good schematic.

If you have made any radio modifications or alarm install these should be disconnected as a first plan of attack. It is entirely possible that the main engine loom has been compromised and will need replacing. Even something from a wrecked car needing minor repair could be better than what you have if it shows other wires have overheated.

Cheers,
GTM