Melting in Littlefuse Mega box HELP

[e28jay]

Hi Guys,

Haven't had a chance to respond or even explain in detail what is going on. I posted the original post quickly and in a panic.

So here is the history.

A couple of weeks ago I started to smell burning in the car. Shortly after the smell, I would have my radio stop working along with a mix of other issues. Including DCS 4x4 Inactive, Trans Fail Safe Mode, the three famous lights (4x4,ABS, BRAKE), hard starting and flickering lights.

Battery tested fine.
Couldn't locate source of smell. It would fill the entire car so tracking it down was hard.
Ran a volt test and with all electronics on and car running at 3k RPM my volts were all over the place. Jumping below 10 and over 13. Never consistent.

So I decided to swap out the alternator. Put the batter on trickle charge and the car was MUCH better but still not right.

Burning smell came back occasionally. And a rare trans fail safe mode. Now before the alt swap this was happening all the time. Could barely drive it a block before something came on. After the swap it was happening about every other day.

Finally located the source of the burning SEE ORIGINAL post.

So I have disconnected the battery, parked the car and ordered a used box and positive cable from a wrecker. Parts should be here by Friday, I'll install on Saturday.

I am really hoping that the alternator was the culprit and fried this little box and cable. I have checked all other wires I can see and made sure grounds were free of any interference after all the recommendations. THANK YOU!

I will report back on Sat.

I do have rear air, so let's hope it is not the compressor.