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Melted red connector plug alternator repair

Started by Old Rider, September 19, 2021, 05:25:50 AM

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Old Rider

Since i have gotten addicted to make silly writeups  i just have to terrorize you with another one  :yes:  so here is my mistakes and repair of the melted red alternator connector.

Pat Conlon

Quote from: Old Rider on September 19, 2021, 05:25:50 AM
Since i have gotten addicted to make silly writeups  i just have to terrorize you with another one  :yes:  so here is my mistakes and repair of the melted red alternator connector.

Keep them coming, we enjoy them!
After comments are made on these informative posts, and the dialog settles down,  I'm saving these over into the File section for easy future reference.

Moral of this story: Use the correct amp rated connector. Check.

However, you gotta ask, why is this connector melting to begin with?
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

Old Rider

Quote from: Pat Conlon on September 19, 2021, 09:44:59 AM
Quote from: Old Rider on September 19, 2021, 05:25:50 AM
Since i have gotten addicted to make silly writeups  i just have to terrorize you with another one  :yes:  so here is my mistakes and repair of the melted red alternator connector.

Keep them coming, we enjoy them!
After comments are made on these informative posts, and the dialog settles down,  I'm saving these over into the File section for easy future reference.
OK then i may have another coming up =)
Saving them to the file section is okay with me


Moral of this story: Use the correct amp rated connector. Check.

However, you gotta ask, why is this connector melting to begin with?

I'm far from a  expert but have done some investigation lately and found that electrical fretting corrosion and vibrations can heat up connectors
Dielectric grease is made to deal with that problems.Found this video
: https://www.youtube.com/watch?v=3Uck9IUIYBQ
and this : https://www.youtube.com/watch?v=6NPMbknRyNE
Also found that the charge from alternator rectifier can get too high because of a corroded contact elsewhere in the wiring like in this video:
https://www.youtube.com/watch?v=sOvBV1z7cZ0

And i forgot to mention that i replaced the connectors one month ago .They still looks good and I'm hoping they will stay good will check them regularly and
post a comment if they start to show signs of heating

Also forgot to send out one of Chuck Norris WARNING again And that is Disconnect the battery before starting this work