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Turned a small problem into a disaster, melted alt wiring
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=5&t=87671
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Author:  Billybob [ Wed Jan 10, 2018 8:33 am ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

Thanks for clearing up this "battery temp sensor" issue.....the KJ documention is not always properly updated so there is often a difference between the Theory of Operations and the wiring diagrams.

I checked the part numbers of the 05 and 06 USA CRDs and they are both: PN 56044672AA as is the 2005 Export CRD.
So no differences there and I have to accept that both USA models probably have the voltage regulators built into them.

Strangely the Export 2006 CRD has a totally different number of: 05142615AA so something changed then as regards the Export models but I will worry about that sometime in the future if an Export CRD owner posts a problem. :wink:

Author:  joe_ [ Fri Jan 12, 2018 6:30 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?

Author:  flash7210 [ Fri Jan 12, 2018 7:13 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

joe_ wrote:
BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?

I don’t see why not.
The fuse should be equivalent to the output of the alternator and the wire gauge should at least be the same.

Author:  WWDiesel [ Fri Jan 12, 2018 9:14 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

flash7210 wrote:
joe_ wrote:
BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?

I don’t see why not.
The fuse should be equivalent to the output of the alternator and the wire gauge should at least be the same.

I totally agree; there are always different options to accomplish the same end results....it's called re-engineering! Do it all the time! :roll:

Author:  GordnadoCRD [ Fri Jan 12, 2018 9:59 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

You might want to try something along these lines

https://www.delcity.net/store/EATON-Mid!Range-Breakers-Switchable/p_823679.h_823680.r_IF1003?mkwid=s7VhDwgyD&crid=38094426869&mp_kw=&mp_mt=&gclid=CjwKCAiA1uHSBRBUEiwAkBCtzTLN48t3E5s3aO7ZMXqO-8GtflYGeoiZ4e0G36Rsz6yPkShOLOt1KBoC9u0QAvD_BwE

rather than a fuse. Get whatever amperage you want. It could save money in fuse replacements if it's something you're having trouble with.

Author:  BodhiBenz1987 [ Sun Jan 14, 2018 10:08 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

Update: I ended up taking the whole wiring harness, plus some 8-gauge fusible link, to a local battery specialist with a good reputation ... they also do wiring. They said it would be possible to do it with a Maxi fuse, and they can do it however a customer wants, but their preferred approach is to replicate the factory setup. So I opted for that. They actually had the fusible link in their shop, but by then I had already tracked some down online so they will use that, and also replace the rest of the alt wire. I should be able to pick it up tomorrow and hopefully everything else will be OK. Still nervous about any possible computer damage but nothing I can do but get it running and see. I could have done it myself but this way all the crimps will be done with the proper tool and I don't have to second guess myself, and can move on to whatever problems are there, or just figuring out the charging issue it had before I did this. 8)

Author:  BodhiBenz1987 [ Tue Jan 16, 2018 7:44 pm ]
Post subject:  Re: Turned a small problem into a disaster, melted alt wirin

I put the harness back in the car, took the opportunity to clean up all the connectors, and so far, so good. It started easily and no lights or codes. I drove it on some errands today with no issues. I'm still concerned about whatever charging issue it had before, but it seems my stupid mistake did not cause any major problems at least. The shop did a nice job, replaced the whole alt wire with fusible link, connectors all neatly done ... saved me a lot of effort without the right crimping tools and whatnot.

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