Okay, so minor (major) issue with my Escape. Apparently there's no cover for the alternator, causing the thing to go bad and melt the connecting wires. Not sure which cover this is and where I can get one, but if I'm gonna go to a junkyard to find it I'd like an idea what it looks like and how to get it out.

The Escape in question is a 2003 4WD XLT with the 3.0L engine.

 

I don't recall my '02 having a cover when I replaced it. (same as yours but 1 year older)
Melted wires can be caused by a poor connection in the crimp where the wire meets the terminal and doesn't neccessariy mean an alternator is bad. The compromised connection cannot handle the current flow and heat is generated.

 

Ken's Tire said alternator was bad and they've never steered me wrong yet.

Now I don't know everything about cars but I'll give a little backstory on the problem:
Was driving down the interstate late Christmas Eve when the problem occurred. First the ABS light turned on, which I thought was weird. Then the radio went out and I sensed there was a problem. But before I could reach the next exit, the whole car lost momentum. All the relevant warning lights came on the car would not accelerate, essentially coming to a stop on the side of the highway.

Now I assumed it was the alternator right from the get-go, especially since my diagnosis at Ken's Tire told me that was one of the issues. The engine had a whine for several months and that's where they narrowed it to.

My uncle's been working on cars for many many years so he offered to help me replace it (and it's a hell of a job). The car still ran after I charged the battery, so I drove it down to his place. But after doing work on it he noticed the wires were melted and and I suppose the alternator seemed to be exposed to the road elements. Now I don't know if there's supposed to be a specific dust cover or something in or around that area, but being that's a relatively expensive part you'd think they'd want to protect it better?

The previous owner did something to the right side of the car before I got it, there's minor issues from a slightly busted grille, pushed up fender or bumper (something's not aligned exactly right), and possibly a crack in the coolant reservoir. So I wouldn't be surprised if they knocked off some protective cover.

 

There is no cover on the alternator its exposed. The whine was the dead giveaway it was going bad. Which wires melted? Take a picture

 

Should be the ones that connect to the alternator. The part's about $20, it has the 3 wires going to it. I'll try to get a photo.

 

Just did my DIL's alt on the 3.0, alt was original by the date sticker and had no cover...seems random whether covers were fitted or not, maybe market-specific???

 

My 2004 had a cover. It was just a small shield. But to get to it you are basically doing the alternator job and I sure wouldn't want to do it in a junkyard.
This guy talks about it at 15:35:

Part number 10 here (looks like the still shot above is the same image as below)::
https://www.google.com/search?q=2004+mazda+tribute+alternator+shield&safe =strict&rlz=1C1CHBF_enUS793US793&source=lnms&tbm=i sch&sa=X&ved=0ahUKEwiMif6DrcvfAhVQX60KHVafAo4Q_AUI DygC&biw=1348&bih=607#imgrc=esupkJIoA_BDgM:

 

Looks like a small splash shield on the wheel arch side? Can't see it affecting the alt wiring temps as they are all on the back next to the exhaust...

 

Yes, but that is a Tribute, might be different. Who knows.

 

It seems it's less of solely an alternator shield and more of a lower engine shield, to hide the serpentine belt and all the pulleys and such from the road. My uncle has one on his 2005 Escape.

Might be the splash shield you're referring to, does it go back far enough to cover the alternator so the fins don't get hit with road dirt and grime and other crap?

 

 

That might be something different then. I think he was referring to something that sits under the right side.

 

I'm not following you, there is no doubt some Escapes/Tributes have the small, plastic alternator shroud (listed as item 10 in the diagram above). ALL Escapes and Tributes seem to have the plastic lower engine bay shrouds, two pieces, one each side that reach as far back in the wheel arch as the drive shafts, the alt is to the rear and above of the RH driveshaft.

If the alternator shroud (item 10) is required to avoid a heating issue then it seems odd it isn't fitted to all. Even if it is fitted it seems to be only on the wheel arch side (to offer additional splash protection maybe), but it doesn't function as a heat shield between the rear of the alternator (where the wiring connectors are) and the exhaust.

So the cause of your melted wiring may not be resolved by fitting the alternator shroud, even if you can find and fit one.

Hope this helps :-)

 

That's fine, I wasn't referring to a heat shield, I meant more in the way of a splash shield like you mentioned, of which a lack thereof may have gummed up the alternator, via the fins.

Sadly, I work in an area with a horrible unpaved parking lot with many puddles, and knowing where my alternator is located I wouldn't be surprise if that contributed to its demise. Also I live in Pennsylvania, where the roads are altogether terrible.

 

Ah cool - I have seen comment that the "shield" is there to promote air flow (and hence cooling), but that may be alternator-manufacturer-specific which may account for why fitting isn't universal.