After my header install, everything seemed to go back together just fine, and then this Saturday when I was driving around, under acceleration, the guages were freaking out and the "check guages" light was flickering on and off. Not being too savvy with electrical stuff myself, I was not looking forward to figuring this one out, but it turned out to be fairly easy.

Apparently when I put my alternator back in, I did not pay attention to the routing of the main power wire that runs from the positive side of the battery. It happened to be resting against the serpentine belt and in 50 or so miles had worn through, and was barely hanging together when I noticed it. I figured that when I would accelerate hard enough, the wire would swing back into the belt and screw up the connection enough that the voltage to the PCM was unstable and freaking everything out.

So I cut what was left of the wire and re-spliced the two pieces back together using a large in-line butt connector and routed it out of the way.

My question is, will I have any problems keeping this repair permanently, or should I spring for a new wire from the positive battery terminal? The battery guage (voltmeter?) was showing above the center line in the "safe" zone after the fix.

Thanks.

 

Either solder the wire together and then shrink wrap it to protect it from the elements or just spring for a whole new wire. Makeshift electrical repairs can either work or just cause problems. If it shorted out its possible it could damage other electrical components.

 

I wrapped the new connection in electrical tape, but it still seems a bit ghetto to me. I've had electrical trouble with cars in the past, so I know the value of repairs done half way. I'll probably replace it, but am hoping that it will work temporarily.

If I get a good volt reading across the battery when the engine is running, would it be safe to assume that it is working?

Thanks again

 

I wouldn't leave it like that for long. If you can't solder it, its not a good fix. A replacement should be pretty inexpensive anyway.

 

You can test the resistance in the wire with an ohmmeter if you have one. That would be the best bet to see if the connection you made is good. It should read almost 0 ohms. But if it isn't soldered and shrink wraped buy a new wire.

 

I picked up a replacement positive cable from a local Pontiac dealer yesterday. The thing was about $50 (probably should have called Jason Cromer), but I'd much rather be safe than sorry in this instance.

I had a Bronco that I sold because of electrical problems, so I don't want to head down that road again.

Heck, I'm just glad I found the problem this time.

Thanks for the help guys.