Melted bolt on alternator!

[SolobaricX]

Also I do have high quality terminals on there....they are the monster 1/0 guage crimpless compression terminals.

 

[benzmansl65amg 10+ year member]

I would complete the big three that would increase your voltage and possibly stop the problem. That would lower resistance big time...

 

[RJesus 10+ year member]

no, your problem is the fact your using 0 awg wire on your charging stud.... its causing a bottle nose effect, and its building power at the bolt... so. what I suggest, is taking and replacing the 0 awg with a 4 awg line. I had the same problem in my 2005 dodge dakota, we have the exact same denso unit alt.
some people are able to get away with running 0 awg. but they just get lucky, You are creating a max discharge right at a cheap bolt... so if you take and replace the 0 awg with 4 awg, but run more than one stand, you will be fine,

I run a single 4 awg line in my truck now, and it does just fine,

so again, this problem isn't the alt, nor the system but simply the wrong wire size for the alt.

Thats pretty retarded. I'd get a new bolt instead. Get one made of a respectable material off of another alt. Just go to the junk yard and find one and take the bolt off of it.

 

[SolobaricX]

All good advice.....the bolt was replaced with a "respectably constructed" bolt which is meant for alternators.....but that didn't fix the problem. When I broke it down earlier today it had already started to melt and burn the plastic coating of the wire. So I took it all off and ran 4 ga. I didnt have any 4ga terminals so I kept the compression terminals and made the 4ga fit (just stripping back a little extra wire and stuffing it all into the terminal)....

I also ran a 4ga ground from the alt bracket to the wheel strut support. I cranked it up and had the system at about 75% of normal playing volume and let it run for less than two minutes....after shutting the engine off the compression terminal at the alternator was SUPER hot. None of the other terminals were hot in the least bit....

I also am going to have to replace that bolt on my alternator again b/c the nut was already in the process of being melted onto the bolt.

 

[SolobaricX]

I have been looking at a 300A Iraggi alternator.....

300a ALTERNATOR 05 06 07 08 09 Commander Grand Cherokee : eBay Motors (item 220485473617 end time Apr-22-10 21:43:50 PDT)

Anyone think this would fix the problem or would this stud most likely suffer the same issues?