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Hi guys, where to begin…
I have a 2002 Ford zx2 that is having horrible electrical issues, and here’s how it started:
1. driving down the highway I turn my left blinker on and the car hesitates HARD, just for a split second, then it drives fine but with no turn signals or blinkers. The 10 amp fuse was bad, but didn’t show signs of it being broke/blown. The car did this twice, each time I replaced the fuse and it ran good for a while. (weeks)
2. Going to work the battery light would come on at a certain rpm, and I knew the alternator was the original and needed replaced, but need to wait a few more days until I could find the time to do it. As each day goes by the light comes on at lower rpm’s, until the alternator died out on me while in my car on my lunch break with the ac running. The tach said 0 rpm, and the car was trying to stall out but would jump up the revvs until I turned it off.
3. Changed the alternator and the car seemed to run fine in the parking lot…let it run for about 15 minutes then drove it around the parking lot, all seemed well until I turned the headlights on and they both instantly blew out. Fog lights that I had on the car for years worked, so I was able to drive it home.
4. I drove the car up and down my road a few times, and took it on a few short trips and it seemed to run OK, then one day the tach went to 0 as I’m driving, and we smelled/heard fuses popping, then the car died, and blew the main fuse under the hood. The plastic around it was melted, and we had to literally destroy the fuse to get it all out. Replaced main fuse, but then the wipers will stay on until I remove the fuse or unplug them. Drove it home, replaced headlights which worked, and haven’t really moved it since.
The car blew numerous fuses during all of this, and the day it killed the main fuse it smelled like wires melting, and blew about 5 others. I’ve inspected the harnesses under the hood and from the alternator and didn’t see any signs of physical wear. Also, behind the fuse box inside of the car looks fine. I’m assuming there’s a short somewhere, and have electrical diagrams but never used them to troubleshoot, and don’t know much about electricity in the first place. Any suggestions?
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You clearly have physical damage to wiring somewhere. To find this will involve physical tracing out of the wires. One tactic I use when confronted with multiple eletrical symptoms, which almost always leads to a single cause, is to pick one symptom that is easy to follow and trace and stick with that one. This will lead you to the whole problem 99% of the time.
ok, thanks for the tip. I haven’t checked it yet, but could an O2 sensor wire that’s damanged cause all of this? It’s pretty close to the ground/exposed to the elements more than most. Today I plan on getting under it and taking a look if weather permits.
I don’t think that one wire by itself would cause it, unless it was part of a damaged bundle of wires. Have you had any bodywork done to it recently? If so, then you would want to check where any body panels might be crashing a wire harness.
[quote=”twiggy02919″ post=32292]I don’t think that one wire by itself would cause it, unless it was part of a damaged bundle of wires. Have you had any bodywork done to it recently? If so, then you would want to check where any body panels might be crashing a wire harness.[/quote]
It had body work but it’s been at least a year. When I get home I’ll give it a good looking over and report back. This electrical issue seemed to come out of nowhere, and the car has always been perfectly reliable. Thanks for the suggestions!
It could take time for the problems to rear it’s ugly head after the body work, if that is the cause.
if your blowing fuses then something has a short or
is over amping that circuit.here is a link for a wiring
diagram.you will need to see whats on that circuit and start
isolating devices.I would suggest going to the auto part store
and buying resettable breakers.this way your not wasting fuses
and money.Based on your description I’d be looking at the big stuff like the leads going to the battery. The fact that it effects so many systems would indicate the problem you have is on the main line somewhere. Make sure your alternator is hooked up correctly. Also make sure it’s a quality unit, a crap rebuild can kill you here. Here’s a video showing how to check the charging system that might also help you with your diagnosis.
Thanks for the suggestions guys! I kept suspecting the alternator, although it tested good…I’m going to look for a short today since it’s going to be nice, then when I get a chance take the alternator back and get it replaced. I’ll keep you posted!
a ?, if it was indeed the alternator that did it, which was a reman unit from pep boys, and it in turn damaged things like the fuse box, is there a way to prove it, and maybe hold them responsible for “damages”? I’ve spent a lot of money, and missed work because of this issue.
First do some testing, use the test in the above video to see what the alternator is doing.
As for being able to prove an alternator caused damage to your vehicle this will prove VERY difficult. Since you’re not a professional technician your skills will come into question, they will use your lack of experience and skill to argue it was something that you did to cause the failure. I’m sure they have better lawyers than you, the most you could hope for is a settlement.
That said lets not put the cart before the horse and see if you can nail down what the problem is with your car first.
I returned the alternator and swapped it out for a new one, put it on the car and when I turn the key to the on position the air bag 10 amp fuse blows. Everything seems to work fine besides that, but I haven’t really driven the car. The times that it malfunctioned on me it seemed ok, I took it for a short spin and then all of a sudden it started blowing fuses, so I’m not very confident yet. Today I’m going to buy a multimeter and hopefully get to do some testing soon!
It sounds like you’ve got a dead short somewhere.
I know this sounds strange but is your windshield leaking or has it been replaced recently? I have seen more than one occasion where water would run down the inside of the vehicle and collect in the fuse box causing all kinds of problems.
I don’t think so but I could be wrong. If it was leaking would it be obvious/easy to find? I can look today after work.
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