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Old 10-10-2009, 07:54 PM   #1
PUDman
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Default melted wire at starter relay

Put a new battery in my 86 gt vert, and when I hooked up the negative cable the section of wire shown in the pic just melted within a few seconds. Nothing happened to the fuseable link. I replaced the link with a 30 amp inline fuse, and now when I hook up the negative cable it blows the fuse. I did a continuity check from the fuse back, and all checks good. The wire is #37 on the wire diagram 10 gauge and it goes to the #1 and #10 fuses; fuel pump relay, and the ignition switch. so now what? Is a 30 amp fuse too small? I'm hoping that's the problem. By the way the 3G upgrade was done over a year ago.

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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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Old 10-10-2009, 08:10 PM   #2
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You have a dead short somewhere that you'll need to trace down.
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Old 10-10-2009, 10:08 PM   #3
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can you suggest where to start? I did all the places I think the particular wire feeds to
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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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Old 10-10-2009, 10:36 PM   #4
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it's on the wire that is popping the fuse
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Old 10-10-2009, 10:52 PM   #5
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is there any other places that wire feeds other than what I posted. I get 0 continuity at all places. Is this the correct way to be checking for shorts?
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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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Old 10-10-2009, 11:53 PM   #6
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to test for a short you must remove power from that leg of the circuit, and one end of the ohmmeter goes to ground and the other to the B+ leg of the circuit being tested, if you obtain a low resistence reading, then there is a short on that leg of the circuit and you should begin tracing the wire from that point back, looking for a chaffed wire or broken insulation that is allowing the wire to ground out on another conductor.
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Old 10-10-2009, 11:59 PM   #7
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what is the B+ leg of a circuit?
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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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Old 10-11-2009, 02:07 AM   #8
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Positive Battery = B+
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Old 10-11-2009, 02:12 AM   #9
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thankx for the help guys. give it a shot tomorrow. I'll post my results
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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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Old 10-12-2009, 12:03 PM   #10
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I have found the gremlin. I had used my fog light switch as a fuel relay kill and one of the wires got pinched under the seat track. finally learning how to read wire schematics it should have only taken but a few minutes to find. Thanks for everyones help
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1986 gt vert 5 spd. 370,000+ original miles. (only engine work done..timing chain twice). original tranny, rearend, etc. original owner; daily driver 300 miles a week. (still passes calif smog legally!!) gotta love a mustang
FMR "C" springs; strut tower support; g- load brace; welded full length sfc's; kyb shocks/struts/quads; 6 pt.roll bar; 5 pt. Diest harness; msd 6a ignition; 3g 150 amp alternator
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