Replacing wires at starter
Thread Starter
Intermediate
Joined: May 2017
Posts: 28
Likes: 3
From: Cleveland, OH
Replacing wires at starter
So I finally took my C4 for its first drive from where my Uncle had it and drove it home. Ran pretty good, idles a little rough. Thought I took care of the valve cover leaks, but passenger side was still leaking. Anyway that coupled with the obscene amount of oil coating everything already decided to cause a small fire. Completely melted the connector and plastic end of my cooling fan temp sensor, melted every last bit of insulation off the wire that runs to the connector and melted the insulation on the 3 main wires that tie into the large post on the starter that are crimped into that ring connector. So the wires after the little black tube that they all have are most of the way exposed. Are these just fusible link wire? Could I just cut them out, splice new wire in and just crimp them into new ring terminals or are there better options?
Supporting Vendor
Joined: Oct 2004
Posts: 761
Likes: 68
Omg
So I finally took my C4 for its first drive from where my Uncle had it and drove it home. Ran pretty good, idles a little rough. Thought I took care of the valve cover leaks, but passenger side was still leaking. Anyway that coupled with the obscene amount of oil coating everything already decided to cause a small fire. Completely melted the connector and plastic end of my cooling fan temp sensor, melted every last bit of insulation off the wire that runs to the connector and melted the insulation on the 3 main wires that tie into the large post on the starter that are crimped into that ring connector. So the wires after the little black tube that they all have are most of the way exposed. Are these just fusible link wire? Could I just cut them out, splice new wire in and just crimp them into new ring terminals or are there better options?
Zen Vet Master Level VII
Joined: Mar 2016
Posts: 5,218
Likes: 1,174
From: Southlake, TX
Your wires have been comprised by an electrical fire.
If it were me, with your wallet, I'd replace the whole wire harness for the starter. Cutting a splicing will just beg for more issues.
Get a power washer and clean off the oil as it can (and apparently will) help create a electrical problem.
If it were me, with your wallet, I'd replace the whole wire harness for the starter. Cutting a splicing will just beg for more issues.
Get a power washer and clean off the oil as it can (and apparently will) help create a electrical problem.
Thread Starter
Intermediate
Joined: May 2017
Posts: 28
Likes: 3
From: Cleveland, OH
Your wires have been comprised by an electrical fire.
If it were me, with your wallet, I'd replace the whole wire harness for the starter. Cutting a splicing will just beg for more issues.
Get a power washer and clean off the oil as it can (and apparently will) help create a electrical problem.
If it were me, with your wallet, I'd replace the whole wire harness for the starter. Cutting a splicing will just beg for more issues.
Get a power washer and clean off the oil as it can (and apparently will) help create a electrical problem.
Well I at least redid all the wiring down there. Found some 14 gauge fusible link wire at O'Reilly's. Cut out the old fusible links and made new ones. I see they were a mix of 12 and 16 gauge. So when I get some 12 I'll redo that one. Undecided if I want to remake the 14s into 16s. I might though. Anyway here's some pictures.
Last edited by duowing; Jun 11, 2017 at 07:29 PM.
Team Owner
Joined: Sep 2003
Posts: 25,373
Likes: 2,734
OP - your links look to be those of likely an '85 or maybe an '84 where all links run from the starter so it's very important to use appropriate sized links etc. Physical "appearance" of the links shouldn't be confused for sizing/amperage.
What year is the car and do you have a FSM (Factory Service Manual)?
There's potential ways to maybe use a "buss" to replace and improve the distribution scheme but it's likely a decision based upon personal preference and prior damage.
What year is the car and do you have a FSM (Factory Service Manual)?
There's potential ways to maybe use a "buss" to replace and improve the distribution scheme but it's likely a decision based upon personal preference and prior damage.
Thread Starter
Intermediate
Joined: May 2017
Posts: 28
Likes: 3
From: Cleveland, OH
Car is an 85. I actually wouldn't mind rerouting them all from the starter. I actually ordered 16 and 12 gauge to replace them. I do have the FSM . Everything behind the labeled black connectors was fine. I taped them with different color tape so I knew which ones were supposed to be 12 and 16. So it's something I'm not too worried about as far as replacing. I don't solder any of these. I have a nice ratcheting crimper. I use the non-insulated butt connectors, crimp them, then use heat shrink. I'll have to see how those are routed to see where I can redirect.
Last edited by duowing; Jun 12, 2017 at 11:43 AM.
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