The problem I have is that, for some reason, the charging wire going from my alternator to my battery is too short. Because it's so tight, any movement of the engine tugs on the wire which causes it to break. It has broken 3 times now at the ring terminal on the alternator. I was thinking of two possible solutions.

1. Snip the wire on both ends, cover with electrical tape so it wont short anything out. Replace the entire length of wire with a longer piece of the same (or heavier) gauge wire.

2. Snip the alternator end of the wire cleanly, somehow attach another short (3-4") length of wire to the existing piece and connect it to the alternator.

The problem with #1 is that I have no idea if the wire splits anywhere because it disappears underneath the intake manifold and I lose sight of it. I also dont know where it connects on the battery side or if there's a voltage regulator in the wire itself somewhere or if it's contained in the alternator.

The problem with #2 is that Im not even sure if it's possible to add another piece of wire like I have in mind. I dont know how you would do it so the charge would continue through the wires cleanly.

Any ideas guys? Ive now missed 3 track days because of this, not to mention having my car towed twice (and possibly a 3rd since it's in my garage now) and I really want it fixed once and for all.

 

Damn, no thoughts?

I think at this point Im going to try replacing the whole wire, I just hope nothing else is spliced into it.