2000 windstar charging

[PiliAloha]

howzit bruddahs, i have a 2000 3.8 LX. A couple of days ago my #10 fuse blew. (ABS lite on, no A/C, no odometer, no speedometer - found it to be 10 amps, owners manual say 15 amps) Anyway, I found that my positive batt cable was extremely hot (melted "Hot Wax" seeping from batt cable). Tested output of alternator to be 17.21 volts. Went to Checkers, a for $200 got a lifetime replacement. Now puts out 14.2 volts. However, fuse blew again today. I found that with the A/C on, battery cable still heats up. Turn the A/C off, cable starts to cool off (all this w/ the engine running of course, and the negative cable always cool). So with that in mind, could it be: the A/C drawing too much current, over charging alternator did permanent damage to batt cable (causing too much resistance in the wire), a short somewhere in the A/C system, new alt still putting out too much volts, or i simply should stick to the garage in my grand turismo 4?
Any and all comments/help/advice would be greatly appreciated, thanks.

[CoachKarl]

PiliAloha,

My guess is . . you fixed cause of the problem when you got that new Alt/Regulator, but that you melted a wire or two in your harness as well. Hot wires indicate that a tremendous amount of amperage is being carried to ground, a "short" circuit. Check to see if that battery cable is touching the body of the van. Better yet replace it. I'd bet that something melted in that A/C circuit. One of those small wires in the harness melted itself to ground too. Open and inspect the harness wires that go to the A/C. Also check to see if you have any melted connecting clips. This is a tedious job, but, it can be done in your garage.

Karl

[12Ounce]

Ditto to above ... I would also add: the hot alternator may have wiped out the battery. Check for overnight voltage drop on battery ... should not go below 12.5+ volts before start-up.

[PiliAloha]

Thanks Coach K & 12 oz., I did try to replicate a large electrical draw by turning on everything (aside from the A/C) e.g. radio, headlights, cabin lites, etc. and the pos batt cable stayed cool. I also switch the A/C clutch relay w/ horn relay, ran A/C sys - still got hot pos cable. Just wondering, if there is a short in the sys, wouldn't the fuse for that sys blow, immediately? The voltage of batt in the mornings is 12.65. Were would the "melted connecting clips" be located; in what area? Looking at the pos batt cable, there are 3 leads that come off the pos batt terminal; 1 to the alternator (which has fuseable links in between), 1 lead goes to the starter ( i think; it sort of goes downwards, under the engine) and the third one goes to the power distribution box. Is there another parts dealer that would have a more economical price structure than Ford? I don't think Checkers or NAPA's would have that batt cable. ( its a 1 piece batt cable that looks like an octipi) Again, thank you all very, very much for your time and advice.

[12Ounce]

I think you're on the right track of suspecting cable failure. Use your voltmeter to measure the voltage drop from one end of cable to other end of cable ... when under full current draw. Compare to the drop on the ground cable .... or, on a cable in some other car. I would expect .1 volts or less on a good cable.... but, I'm guessing.