Alternator cable melted - how to replace

[stanman77]

This is a 98 3.0 Windstar. I lost all power and found that the heavy gauge cable from the alternator to the wiring harness is burned at the point that it attaches to the alternator. I have removed the alternator for testing and was in the process of removing the burned cable, but it seems to be connected under the bank of fuses. When I say burned, it looks like there might have been some arcing where it attaches. It burned the metal at that point, but the rest of the cable jacket seems fine beyond that point.

Can I replace just the end of the cable and make a proper slice connection?

If not, how do I get the fuse box removed to detach the cable?

Is there some other way to detach the cable, so I can replace it with a new one?

Thanks.

[stanman77]

Well here is how I fixed it. I went to the boneyard and picked up a working alternator. They cut the main wire back to the harness instead of detaching it. Therefor, they left the rubber boot and connector that I needed on the alternator for free. I just went to an alternator shop and bought an new crimp on termimal and adjusted my existing wire to give me an extra few inches. I solder the wire onto the new crimp connector and then used good automotive electrical tape to seal the wires that the rubber boot did not cover.

It has been working fine for several weeks now.