Wires melting

[BigSHO]

Well I avoided the issue long enough. I was informed by IFSJA that I needed to disconnect the amp meter with a higher output alternater. But did I listen NOOO so here I am asking for info on the two melted wires the yellow and red one that both come from the starter selenoid.

Question 1.
Do those wires do anything else than just the amp meter?

Question 2.
Do I have to replace the wires or just tear them out of the Vehicle.

Question 3.
Wow there are alot of wires in an 84 wagy and yet I have no power options at all? this is not a ? but I do ? jeep wiring.

I know you are going to tell me to buy a wiring diagram(spelling) but I have a love hate relation ship with instruction. They never tell you enough or they tell you to little. Or they tell you colors that are wrong.

Another reason is that the PO seemed to have rewired it some what because of the duct tape I found in the harness which I hope was not Original.

So anyinfo on how to fix this would be appreciated. Thanks

[jode]

Wiring has me in the same boat...wish I could tell you anything conclusive on the matter....investigation may be the only way to figure this one out (tracing the wires to the source :( )

Sorry to be of so little help :confused:

[timmirvin]

Well I am glad you brought this up.....but not so glad you already have melted wires.

I was just addressing this on another thread and was about to ask just what i needed to do to keep it from happening to me......

So I think I will wait for one of the "I've already done that" Gurus to chime in and we will both learn!!!!!!!!

tim

[Bob Barry]

Originally posted by BigSHO:
Well I avoided the issue long enough. I was informed by IFSJA that I needed to disconnect the amp meter with a higher output alternater. But did I listen NOOO so here I am asking for info on the two melted wires the yellow and red one that both come from the starter selenoid. We instituted a no "We told you so" policy about four years ago. Something about conserving bandwidth... ;)

...plus it seems that FSJ owners are, by nature, gluttons for punishment and actually PREFER learning things the hard-way.

Originally posted by BigSHO:
Question 1.
Do those wires do anything else than just the amp meter? Yes; they are the circuit by which the alternator recharges the battery.

Let me repeat that.

You see that 10-gauge red wire that melted its insulation to itself all the way from the alternator to the firewall bulkhead, from the bulkhead to the "Big Splice", from the "Big-Splice" to the ammeter, and the 10-gauge yellow wire that runs from the ammeter to the firewall bulkhead, and then from the bulkhead all the way to the starter relay on the passenger-side fenderwell?

That sixteen feet or so of 20-year old wire running directly through a 20-year old ammeter?

THAT is the SOLE circuit through which the alternator charges the battery.

THAT is why you NEVER jump-start an ammeter-equipped FSJ and let the engine "charge-up" the battery. On our trucks, that effectively chars-up the wiring harness and ammeter.

Originally posted by BigSHO:
Question 2.
Do I have to replace the wires or just tear them out of the Vehicle.At the VERY least, you have to pull apart the harness, repair the wire from the alternator to the firewall to the big splice, and any other wires it took out in its electrical hari-kari act. That wire to the "Big Splice" is the main source of power to the whole Jeep.

Then you have to make a decision: How are you going to charge your battery?

You could replace the rest of that red wire, and the burnt-up yellow wire, and just hook them together directly to bypass the ammeter. Or you can run a heavy-gauge charging wire directly from the alternator charging-post to the (+) post on the starter relay, so that you cut out about 15' of wire. Add a fusible link to that bypass charging circuit, for protection in case it shorts out against anything. I did mine in 10-gauge, but I would probably use 4-gauge wire if I were to do it again.

As for that yellow wire, you would cut it out right after the splice where it joins into the resistance wire that feeds the alternator plug.

Originally posted by BigSHO:
Question 3.
Wow there are alot of wires in an 84 wagy and yet I have no power options at all? this is not a ? but I do ? jeep wiring. The more you see of Jeep wiring, the more you will question it.

Originally posted by BigSHO:
I know you are going to tell me to buy a wiring diagram(spelling) but I have a love hate relation ship with instruction. They never tell you enough or they tell you to little. Or they tell you colors that are wrong.

Another reason is that the PO seemed to have rewired it some what because of the duct tape I found in the harness which I hope was not Original.<sigh>

Believe it or not, most duct-tape you find in the wiring harness IS original. Notably around that "Big Splice". Yes, factory-installed DUCT tape. But heck, I remember a few years back somebody *insisted* that the ammeter MUST be a shunted-type, because NOBODY would run a whole charging circuit DIRECTLY through an in-dash ammeter... :rolleyes:

Glad it wasn't worse for you. We've all been there.

[timmirvin]

<Pushing "PRINT" now>

Thanx again Bob, I am just hoping that this hasn't already happened to Sherman.

[timmirvin]

So, Bob, being the Guru that you are, I now have a question for you.

Once I get in from offshore, putting my newly purchased wiring harness (thanx Craig) on is my first priority. Then going thru all the steps to start Sherman are next. By-passing the ammeter has become one of them.

My question.....is there a way I can use the stock, already in the dash, meter???

Can it be put in a parallel circuit?? Can I hook it in like a volt meter??? You get the idea??

Having another gauge/meter mounted to the dash will not be a big deal (already planning tach, trans fluid temp, oil temp, etc), but was just wondering.....

TIA
tim

[Subconscious]

Are the later models with voltmeters, instead of ammeters, wired in this same crazy fashion?

[2nd Day]

THAT is why you NEVER jump-start an ammeter-equipped FSJ and let the engine "charge-up" the battery. On our trucks, that effectively chars-up the wiring harness and ammeter. Amen to that, specially when the "dead" battery is pushin 12 volts...had a similar problem...

[Crazy_Jeepman]

Soon as I seen the Title of this Topic..................I knew what Wires were melted :(

[Bob Barry]

Originally posted by timmirvin:
My question.....is there a way I can use the stock, already in the dash, meter???I don't know of any way to re-use the in-dash gauge. If you did hook it up via a shunt, it would have to be re-calibrated, but I have no idea how that would be done.

I've seen aftermarket voltmeters that have the needle sweep downward, and I've considered stripping it out of its housing and seeing if it could be adapted to our stock dash, but I'd probably do a custom dash with voltmeter before I did anything like that.

[AMC258]

Well after this thread, I'm just more confused, the red wire on mine is fried, I disconected it, but the ammeter still works, and the battery still charges, WOOOOHOOOOO! Looks like I get to hack into it and see what's going on.