Smoking bulkhead connector

[cwhubb]

I was jump starting my 70 charger when a little whisp of smoke came out of the engine harness connector where it snaps in the the main bulkhead connection. The thick black wire with the tab thats says "safety" on it was melted where it enters the connector on the end of the engine harness, (not the main bulkhead connector)

1. How do these wires attach/connect to the plug side of the harness?
2. Is the melted wire a fusible link?
3. If it's a link who sells them?
4. How can I repair this?

Thanks
CW

 

[440roadrunner]

You sure you didn't have the cables hooked up backwards? There is no reason that jump starting one of these cars should result in that problem

Sounds like you blew up (or damaged) the fuse link. You can get fuse link wire from any decent parts store, don't know if you can get "ORIGINAL" ones or not

PLEASE read this article on the hows and whys of bulkhead connector problems

http://www.madelectrical.com/electricaltech/amp-gauges.shtml

Whether you are interested in the bypass or not, there's a good explanation there of how and why these connectors fail.

So far as getting it apart, there are clips? latches? that are part of the connector you see on the engine side. You release them, and the sections of connector come right off

Before you worry about repairing, find out WHY. You might rig a lamp in series with battery ground. Temporarily clip lead a jumper across the bad fuse link, and make sure all electrical is off, and don't forget dome, courtesy, and trunk lamps. If the lamp lights, you have a drain or short somewhere.

Pull the fuses one at a time, and if the lamp is still lit, unhook the alternator output wire and tape it off. You may have shorted one of/ some of the diodes.

 

[RustyRatRod]

The firewall connector is the number ONE source of resistance in an older Mopar. The fact that you were jumping it off probably made no difference. Over the years, the connectors get oxidation and dirt between them and ultimately lose connection, or as you almost found out, cause a fire.

If you unplug the connector, look into the part that plugs in and you'll see the brass connectors for each individual wire. On those brass connectors, there are little "prongs" that snap into place when each one is installed into the connector. You have to get a small pick or screwdriver and release the prongs while gently pulling on the connector and it will come out. Look at it closely and you'll see. It's not difficult.

If the fusible link toasted, simply get some more in the same gauge and splice it in. Also, go back and remove all the grounds, clean them up GOOD, reinstall them and paint over them to assure they do not rust.