Melting in Littlefuse Mega box HELP
 

Hi Guys,

The positive battery cable has melted where it connects to the box which holds the littlefuse mega. Any ideas why?

Poor connection. It must have been loose or corroded/oxidized.

^That was my guess... something caused increased current draw through the cable.

Definitely bad connection. Clean it up really well with wire brush etc, apply an anti corrosion/di-electric grease and keep an eye on it.

I've never had to open mine...but the pics sorta show the nuts are nyloc though ? Don't see that backing out

I have opened mine to do my amp install. They are not nyloc. Unless I am going senile and don't remember. Which is always possible I must admit. ;)

Don't forget that there is a chance that the excessive resistance is/was in the crimp for the battery cable lug. If you don't have the equipment to make sure the cable is good you might want to replace it, or have a new section crimped on. I think you can get the connection box from a wrecker pretty cheap so I would just replace that.

Heat is caused by resistance, check & clean all grounds, also does your truck have air suspension? Had something similar happening to an 04 range rover, similar setup. Compressor overworked causing overheating and to much current being drawn. You should also consider replacing that part.


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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.

The culprit is the connection itself. Changing the box and the battery cable will fix it. If it was anything else the fuse would have blown.