Electrical Issue - how to locate problem

Gas is too freakin expensive!!!

So, I finally decided it was time to ressurect my 1990 Geo Metro. I put new piston rings in, replaced the tranny, all filters, battery, plugs and wires, etc. etc. I am having the same problem I had before I fixed it up. The battery light comes on intermittantly. When it does, I have about 2 hours worth of driving before the battery goes dead. It seems to happen when I hit a bump or pothole. I have had the alternator tested, it came out great. I have also tested the battery,(its brand new anyways) its good. I am assuming that the problems is due to a bad ground or loose connection somewhere. I am wondering if anyone has any suggestions on locating the problem? I've tried pulling different fuses and starting the car to see if I could locate the faulty circuit that way, no luck. How should I go about this?

ANY help or suggestions would be welcomed. Thanks

The fuse box under the hood has a bad habit of burning up positive plugs. There's 2 plugs that go into the 60a fuse under the fuse box. Unplug the one that is closest to the battery, cut the crimped end off, and hook it directly up to the battery, and you'll be all set. The plastic on the plug wears out to the point the terminals don't make contact, and the arc until it melts the fuse box. Also, make sure the other plug doesn't have play in it, cause that'll cause the car to stall when you hit bumps.

I'll check that out. Thanks

I had the same problem with my 96. if you check the fuses and there all good. Check the bottom of the hood. Mine the battery was to tall. so it rubbed the bottom of the hood. What i did to correct it was duct tape some cardboard to the terminals to prevent the contact, until i can get a peice of Thick rubber instead but for now its been about 2 week and has not left me yet. and i'dd like to say I totally agree with you about gas here in forsyth county of North Carolina the 89 is $1.45 ish. im still in high school and dont have a job so money is scarce.

PS i hope this helps, so you can start saving your money.

We are having the same trouble with our 93 Geo, we just put the 3rd. alternator in in a month, also new battery. Runs fine for maybe 4-5 days, tac goes haywire,lights dim, service engine soon light, then nothing. it only has 47,000 miles, engine is quiet as can be. Any ideas what is going on?

Gas is too freakin expensive!!!

So, I finally decided it was time to ressurect my 1990 Geo Metro. I put new piston rings in, replaced the tranny, all filters, battery, plugs and wires, etc. etc. I am having the same problem I had before I fixed it up. The battery light comes on intermittantly. When it does, I have about 2 hours worth of driving before the battery goes dead. It seems to happen when I hit a bump or pothole. I have had the alternator tested, it came out great. I have also tested the battery,(its brand new anyways) its good. I am assuming that the problems is due to a bad ground or loose connection somewhere. I am wondering if anyone has any suggestions on locating the problem? I've tried pulling different fuses and starting the car to see if I could locate the faulty circuit that way, no luck. How should I go about this?

ANY help or suggestions would be welcomed. Thanks

I had the same problem, it turned out to be a bad connection at the alternator HOT terminal. Make sure the CONNECTION at the HOT is CLEAN and HEAVY guage and TIGHTEN the nut down. Its' getting HOT, so after an hour, it'll justs quit putting out power to the battery. I replaced the end terminal with heavy gauge connector and polished the HOT terminal, that cured everything.

Bad alternator HOT terminal connector. Lose or corroded connection. Replace lead into HOT connector with heavy gauge round type 10 gauge, clean, and tighten nut down hard, that'll clear up the problem.