On going electrical problem

[webshot]

Ok this is a spin-off of my alternator question a while back. Ok I just changed the voltage regulator because that tested bad, so I thought maybe that was the culprit so I installed that. Hooked everything back up, went to jump the car, then the starter solenoid got real hot and a slight smoke came from the battery.....wtf??...never did that before, so I am thinking I bought a bad VR. Put another in the same problem. ANd I noticed the started tried to stay engaged after I let go the key....

So I decided that I am going to attempt to rewire the alternator since I notice some of the wires are brittle and some of the fusable links seem to be fried. My questions are:

1. When I run a new wire do I take it all the way back to its origin or do I find a place to cut the wire, and connect the new wire there?

2. I notice the wires have various gauges, do I replace them with same gauge and color?

3. What are pitfalls I should look out for?

I am going to find a chiltons or something to help me with the schematics. After looking around I feel this is something I could do. So I am going to make it my week end project. Oh BTW the car is the 84 from my sig.

 

[jrichker]

AutoZone wiring diagrams

http://www.autozone.com/servlet/UiB..._us/0900823d/80/16/71/3c/0900823d8016713c.jsp for 79-88 model cars

http://www.autozone.com/servlet/UiB..._us/0900823d/80/19/59/5a/0900823d8019595a.jsp for 89-93 model cars

http://www.autozone.com/servlet/UiB..._us/0900823d/80/1d/db/3c/0900823d801ddb3c.jsp for 94-98 model cars

Use the same wires sizes or large than the orginal. The color is used to trace the wires, so make your own desisions about that.

Running a wire from start to finish is a lot neater and less prone to problems than splices.

SwAmPf0x: how to wire a 3G in an 85 or earlier Mustang
cut and paste from an old post of mine...

There are 4 wires to the voltage regulator, cut the plug off the regulator, extend the 2 wires used to the alt and cap off the other 2

The F will not be used.
The I will not be used.
The S will go to the 3G
The A will go to the 3G

wiring on the 3g side

The Big post on the back goes to the solenoid, same side as the battery, a fuse is recommended on this wire, also up the wire size to 4ga minimum

Now for the 3 wire plug...wires A,S,I

A goes to A from the old external regulator
S goes to the stator connector on the 3G
I goes to S from the old external regulator.

 

[webshot]

thx jichkter.....I am not going with the 3g yet. I am going to fix the current system then upgrade. There are quite a few burnt, cut and brittle wires littereed around the solenoid and alternator so gonna clean things up first. But thanks, definate book mark thread.