melting wire please help

[marki2013]

hello people, i need some seriour help

ive fitted a new turbo n front mount intercooler, took my car for a spin and every time i was braking the FOG light kepet coming on an the clocks light n i got home and poped the bonnet an looed at the fuse box on top of the battery an the wire from the fuse box to the alternator was melting really bad

why is this happening? please help

[Crashy]

I reckon when you were fitting your front mount you drilled through into a wire.

[oakdale]

As the fusible link doesn't appear to have failed it's quite likely that this has been caused by a bad connection at the terminal nut.

That terminal will be carrying a heavy load and if there is a resistance at that point it causes heat which in turn causes more resistance and it then becomes a vicious cicle until the wire melts.

Also all the terminals look like they need removing cleaning up to me

[wolf1]

It's a common fault due to voltage drop/resistance causing heat build up and the result is in your pic. Buy a new fuse box and trim the crap section of wire back and crimp a new fitting on. Make sure all the connections are clean and shiney before assembling.

[Locknut]

What about his fog light coming on when he brakes? That could be a bad earth or a wrong bulb fitted.

[ADEuk]

Locknut said:

What about his fog light coming on when he brakes? That could be a bad earth or a wrong bulb fitted.

+1
Check for a single filament bulb where a 2 filament should be in the rear clusters

[PaulKemp]

Lights coming on ( or going off) randomly usually points to an earth fault check all major earths you may have disturbed earth from battery and other major earth straps such as engine and gearbox to chassis

[andyiley]

I am guessing your other post

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

Is part of the same issue.

I think you may need to retrace everything you did and check and double check everything you have done as you seem to have likely caused your own problems.

[marki2013]

also after fitting the biga turbo k03s an the front mount intercooler, while i was on my test drive an noticed the FOG, an clock were lighting up, including the trackion control light was lit up, the brake pedal keeped going to the floor when i was at a stand still, please help with with all this

[oakdale]

marki2013 said:

also after fitting the biga turbo k03s an the front mount intercooler, while i was on my test drive an noticed the FOG, an clock were lighting up, including the trackion control light was lit up, the brake pedal keeped going to the floor when i was at a stand still, please help with with all this

You need to fix the problem with that wire first, all sorts of strange electrical problems can be caused by this failing.

If it's a diesel, the brake pedal going right down with the engine runnung but the car stationary is normal.

[marki2013]

erm no its a 1.8turbo, then pedal was ok i fink be4 this wire melted, then it started going to the floor, but im gonea check all the vac hose etc and all earths an clean them up tomorrow and see what happenes

[andyiley]

oakdale said:

If it's a diesel, the brake pedal going right down with the engine runnung but the car stationary is normal.

Surely not! How do you brake if you are in a diesel then?

[wolf1]

andyiley said:

Surely not! How do you brake if you are in a diesel then?

It's called pedal creep. The newer transits do it as well. It's not a case of the pedal goes straight down but with constant pressure applied it will creep down whilst not losing braking efficiency.

[andyiley]

wolf1 said:

It's called pedal creep. The newer transits do it as well. It's not a case of the pedal goes straight down but with constant pressure applied it will creep down whilst not losing braking efficiency.

That symptom sounds like a knackered master cylinder seal to me.

[wolf1]

andyiley said:

That symptom sounds like a knackered master cylinder seal to me.

It's not it's pedal creep as I've already told you. Get in a newer transit and press the pedal down and keep it down, the pedal will slowly creep down. They all do it the seals are fine.

[oakdale]

wolf1 said:

andyiley said:

That symptom sounds like a knackered master cylinder seal to me.

It's not it's pedal creep as I've already told you. Get in a newer transit and press the pedal down and keep it down, the pedal will slowly creep down. They all do it the seals are fine.

Correct, this phenomenum is mentioned in the MOT testers manual and testers are instructed not to fail the vehicle if this occurs.

[PaulKemp]

Pedal creep does not normally go to the floor
Yes pedal creep is a known phenomenon and I have felt it but its never gone all the way to the floor

[andyiley]

I have to admit, I would have alarm bells ringing all over the place as the only time I have ever come across this, it has meant a master cylinder failure.