Alternator Burned Out!!!!
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Senior User
Joined: Aug 2003
Posts: 204
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From: North Andover,MA 01845
Alternator Burned Out!!!!
My question is well today I smelled wires burning and looked under the hood and the alternator was smoking from the big connector where it go's in, I pulled on it and the whole connector came out all melted. But all that is melted is the alternator part of the connecter that is in the alternator, nothing else not even the wires going to it. So what is going on? Did my alt. short out? Please let me know what all you think.
Logistics Pro
Joined: Apr 2004
Posts: 4,292
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From: NJ where fun comes to die
I went through three alternators in two years on my 92. Seems like they just short out now and again. Buy one with a lifetime warranty and you will be covered if it happens again. Good luck.
Elder User
Joined: Apr 2001
Posts: 772
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From: Glen Burnie Maryland
You need to get a NEW CONNECTOR! The wiring on the Ford's are notoriously small for the loads they have to handle and they tend to melt.
Cal Term 08622 is the # for the pigtail. The wiring is at least 1-2 gauge larger than original wiring. Also you can change out the Rectifier bridge / diode set cheap.
Replace the voltage Regulator, Brushes and the Diode pack/rectifier bridge while you have it apart. Clean up the commutator lands (where the brushes sit). Spray it all down with electrical equipment cleaner and a toothbrush to get all teh carbon out. Make sure when you put the rectifier bridge and the voltage regultor in, that the METAL SIDE has a light coating of heat sink grease (same stuff you put on your CPU and cooling tower on your computer.) or the parts will get overheated and you'll be right back where you started.
OR if you're mechanically stunted, go buy a new alternator AND the pigtail. Install as per instructions. I use non insultated butt connectors(crimps), then solder them, then heat shrink each individual wire, then wrap in electrical tape. Makes for a solid connection and it won't burn out.
That's my story and I'm stickin to it!
Larry
Cal Term 08622 is the # for the pigtail. The wiring is at least 1-2 gauge larger than original wiring. Also you can change out the Rectifier bridge / diode set cheap.
Replace the voltage Regulator, Brushes and the Diode pack/rectifier bridge while you have it apart. Clean up the commutator lands (where the brushes sit). Spray it all down with electrical equipment cleaner and a toothbrush to get all teh carbon out. Make sure when you put the rectifier bridge and the voltage regultor in, that the METAL SIDE has a light coating of heat sink grease (same stuff you put on your CPU and cooling tower on your computer.) or the parts will get overheated and you'll be right back where you started.
OR if you're mechanically stunted, go buy a new alternator AND the pigtail. Install as per instructions. I use non insultated butt connectors(crimps), then solder them, then heat shrink each individual wire, then wrap in electrical tape. Makes for a solid connection and it won't burn out.
That's my story and I'm stickin to it!
Larry
Tuned
Joined: Sep 2003
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From: Brighton, IL
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Replace the alternator and the connector going to it. This has been a problem with these for quite sometime. If you get an alternator from NAPA the connector comes with the new one and it tells you to replace it. Make sure you use the silicone gel that comes with it when installing the connector to the alternator. That will help reduce the heat.
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Elder User
Joined: Mar 2003
Posts: 788
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From: Hendersonville, TN
You might have to do some looking in your area to find an alternator shop that will sell you parts, but if you are mechanically inclined this is the way to go. Individual parts at such places are cheap and if you do it right you'll have a better alternator than the "cheapies" at the chain parts stores. See Larry's post above. Good advice, and this is what I always do. I'm a regular customer at an alternator shop here in Nashville and I can go through one for about $40 or less and rebuild it in about an hour. They'll likely have the harness side connector too if you need that.
Freshman User
Joined: May 2004
Posts: 41
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From: Lee's Summit MO
Originally Posted by 1990Fordf150v8
My question is well today I smelled wires burning and looked under the hood and the alternator was smoking from the big connector where it go's in, I pulled on it and the whole connector came out all melted. But all that is melted is the alternator part of the connecter that is in the alternator, nothing else not even the wires going to it. So what is going on? Did my alt. short out? Please let me know what all you think.
Junior User
Joined: Feb 2002
Posts: 91
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From: Brunswick, Ohio
Is the 3G a direct bolt-up part? I just had the alternator in my 88 fry the other day and I replaced it with the one from my 92 parts truck. I have no doubt that it will happen again in the future.
Freshman User
Joined: May 2004
Posts: 41
Likes: 0
From: Lee's Summit MO
Originally Posted by beerinside
Is the 3G a direct bolt-up part? I just had the alternator in my 88 fry the other day and I replaced it with the one from my 92 parts truck. I have no doubt that it will happen again in the future.
