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#1 |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Truck Died Instantly - Electrical Smoke/Smell
I keep my 72 in an off-site shed of mine on high-quality battery tenders for the last 11 years without any issues every. Yesterday, I popped the battery tender off of it, cranked it up and it started just like it always does. I pulled it outstide and let it run while I closed up the shop. It died instantly. No sputtering, just died like you turned the key off which means electrical to me. I raised the hood and instantly saw smoke coming from the battery area and that distinctive electrical smoke smell.
Curious where you think I should start. I have a couple of theories. Either a) my tender overcharged my battery or b) my alternator started overcharging my battery once I started the truck. Stats: Battery voltage checked at 12.53. Battery is 2.5 years old. I think my battery is fine--I'm guessing I blew the fusible link on the fender that comes off of the battery and that is what was smoking. Would you replace fusible link, voltage regulator and alternator? All are at least 11 years old as they have not been changed since I got the truck. Thank you for your expertise! --Mark
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#2 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Sounds exactly like what my truck did a few years ago. I didn't realize it at the time, but I believe the alternator was overcharging. I know it was overcharging later on when we were trying to fix it.
I think you're on the right track -- replace the fusible link, get an internally regulated alternator, throw away the old voltage regulator, and beef up some of the wiring. Only way I got mine fixed was with a ton of advice from great board members here. Gonna give you a link to my lengthy post -- the answers are in there if you can sift through some of my frustrated ramblings. Good luck! http://67-72chevytrucks.com/vboard/s...d.php?t=772236
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#3 |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
Ah interesting. So, no need for voltage regualtor if I get the interally-regulated alternator?
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#4 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Correct. The link I posted tells how to eliminate it. IIRC, a couple wires get soldered together and a couple others are removed.
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#5 |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
Well, here is what I found. The length of wire in the 1st photo that has been melted and literally pulled apart--is this the fusbile link? I believe it is. This would have been what was smoking I do believe as it still has an electrical fire stink to it. The red section of wiring runs up along the radiator support. Also, looks like that voltage regulator is decades old. So, my thoughts are, for now, put a new voltage regulator in (may convert the alternator to internal later) and replace that section of wiring that fell apart. If that is the fusible link, do I solder it back inline and shrink wrap or just a butt connector and shrink wrap? I can do either. Do you know what gauge fusible link to purchase?
Thanks!
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#6 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Yessir, that is the fusible link. It should be 16 gauge. I connected my new one with a butt connector, then made a spare to keep in the glove box -- just in case. Hopefully that is your only problem. Keep a close eye on your voltage and if it shoots up (mine went over 18v) then you have other issues. I burned up more wiring than just the fusible link.
As to replacing your voltage regulator -- before I bit the bullet and converted to an internally regulated alternator, we bought three new regulators and none of them worked. They were not adjustable, and finally the mechanic put the original back on and tweaked it so it would work -- for a little while. YMMV
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#7 |
Post Whore
![]() Join Date: Feb 2016
Location: Portland Oregon
Posts: 11,618
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Re: Truck Died Instantly - Electrical Smoke/Smell
I would do some troubleshooting before replacing any parts. The fuseable link will blow anytime there is an over current condition. You could have a grounded hot lead between the battery and the fuse box or farther down the circuit on an unfused circuit. Maybe rodent instigated.
You should be able to have the alternator and regulator test by a competent auto repair shop. The local chain auto parts store may or may not be able to test an externally regulated alternator. My Burban's factory charging system went into overcharge and the result was it tried to cook the battery. A hot battery acid smell was the symptom I had with no damage to the fuseable link. This link is to my repair thread scroll to post 467 where I start my conversion to a late model alternator. There is some information on fuseable links a couple posts down. https://67-72chevytrucks.com/vboard/...698377&page=19 Good luck and post your findings so we all can learn more.
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Thanks to Bob and Jeanie and everyone else at Superior Performance for all their great help. ![]() RIP Bob Parks. 1967 Burban (the WMB),1988 S10 Blazer (the Stink10 II),1969 GTO (the Goat), 1970 Javelin, 1952 F2 Ford OHC six 4X4, 29 Model A, 72 Firebird (the DBP Bird). 85 Alfa Romeo If it breaks I didn't want it in the first place The WMB repair thread http://67-72chevytrucks.com/vboard/s...d.php?t=698377 |
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#8 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Just found this, maybe it will help.... https://www.whiteproducts.com/fusible-faqs.shtml
Typically, a given harness segment is protected by fusible link that is four gauge numbers smaller. A 14-gauge wire would be protected by an 18-gauge fusible link. A 6-gauge wire would be protected by a 10-gauge link, and so on. Odd number wire gauge sizes like 19, 15, 13 and 11 are counted when sizing a link. The length of a fusible link should not exceed 9". EDIT: HO455, glad to see you on here! You, Andy, VetteVet and others saved my bacon when I had my problems. Always nice to hear from experts!
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay Last edited by Stocker; 07-04-2021 at 07:31 PM. |
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#9 |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
Yah, I thought about the rodent possibility too although I have not found any indications of that yet. Main thing is to get it the two miles from my shed to my actual home garage so I can work on it much easier. This would be a good excuse to upgrade my winch on my trailer to haul the old girl up there and tow her home!
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#10 | |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
Quote:
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#11 |
Registered User
Join Date: Jun 2010
Location: San Diego Co.
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Re: Truck Died Instantly - Electrical Smoke/Smell
I agree that the truck just dying sounds like a fusible link issue, but in pic 1, isn't the fusible link that black bulbous (where the fuse is) mass with the short wire going to the fuse block? That melted red wire is coming from the alternator via the voltage regulator, isn't it?
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1972 Chevy C-10, SWB, Fleet, 350/350, PS, PB, HEI, mostly stock, Survivor. ![]() |
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#12 | |
20' Daredevil (Ret)
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Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Quote:
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#13 | |
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Re: Truck Died Instantly - Electrical Smoke/Smell
Quote:
Is that correct? Shown in green.
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#14 |
20' Daredevil (Ret)
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Location: Jefferson State
Posts: 13,812
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Re: Truck Died Instantly - Electrical Smoke/Smell
Correct on all counts. The item circled in red contains the 4A fuse for the ammeter. You can pull it apart to verify. The solid section at the end of the fusible link contains the splice point, as you said. Cut the red wire where shown. Rather than hard soldering the fusible link to that red wire, consider a butt splice so you can make up a spare. That makes it much easier to replace if it blows again.
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#15 | |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
Quote:
Oh, okay. Butt splice is fine by me if there are no issues with that for longevity. Curious if a 16-gauge fusible link and the thick red harness wire will both fit in the same diameter butt connector on both sides.
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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#16 |
Who Changed This?
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Location: Simi Valley, CA
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Re: Truck Died Instantly - Electrical Smoke/Smell
One thing I'd like to point out before replacing a lot of parts. I've seen brand new cars towed into the shop with burnt fusible links that needed nothing other than the wire replaced. They really are like a fuse, and some conditions cause them to fry, but then don't do it again. Is there anything out of the norm in this instance?
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#17 | |
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#18 |
Who Changed This?
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Re: Truck Died Instantly - Electrical Smoke/Smell
If it were mine, I'd take the truck to a parts store that has the equipment (after you replace the fusible link) and have the charging system checked out while intact. I'd really not want to start tearing into it until the actual problem was evident.
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~Steven '70 Chevy 3/4T Longhorn CST 402/400/3.56 Custom Camper Simi Valley, CA |
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#19 | |
20' Daredevil (Ret)
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Re: Truck Died Instantly - Electrical Smoke/Smell
Quote:
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#20 | |
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#21 | |
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#22 |
Who Changed This?
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Re: Truck Died Instantly - Electrical Smoke/Smell
Right. They can also check that the regulator is working, though it may have to be off the truck for that.
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~Steven '70 Chevy 3/4T Longhorn CST 402/400/3.56 Custom Camper Simi Valley, CA |
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#23 |
Senior Member
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Location: Gods country East,Tn
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Re: Truck Died Instantly - Electrical Smoke/Smell
Safety First Fusible link
You are most likely familiar with how a fuse works in an automobile, but here’s a quick reminder. A fuse serves as a link in your vehicle’s electrical system that can be broken under certain circumstances in order to protect various components and systems from damage. Typically, a fuse burns out when a circuit attempts to transmit too much current, severing the connection before the electrical charge can have any ill effects. A fusible link acts much like a fuse, only it’s designed to handle a different type of potentially hazardous scenario. These links are actually strands of wire wrapped in a fireproof covering, and are thinner than the wiring harnesses they’re connected to. They are placed in-line between delicate harnesses and large sources of electrical current in your car—between the battery and alternator, for example. These links must transmit high-current electricity, but also protect the rest of the electrical system from dangerous spikes that could cause a fire. If there’s a surge, the link actually melts, as its resistance to heat is lower than that of the circuits it’s protecting. This cuts off power while protecting the engine bay from a conflagration, thanks to its fireproof wrapping.
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![]() 1967 Factory short bed - Old school '71 - 350 / 4bolt / 487 heads / Edelbrock C3BX Muncie M-22 4 speed / Hurst Comp plus Factory 12 bolt posi 3.73 / 255-70-15 Smoothed firewall / Factory cowl induction Power disc brakes / power steering / 3.5-5" drop |
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#24 | |||
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Join Date: Jun 2010
Location: San Diego Co.
Posts: 1,193
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Re: Truck Died Instantly - Electrical Smoke/Smell
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About 3 months ago my 8 year old battery gave up. When I was pulling it out, I noticed the red wire from the radiator support loom had a butt connection that was severely corroded. It was so bad that the yellow insulation on the connector was cracked and swollen. See pic below. “No problem”, I thought. “I’ve got all the materials here to cut that out and solder in a new section of wire to reach the block on the fender.” I’m now understanding that I have eliminated the fusible link! No wonder the wires on either side of the old connector looked different! Doh!! I just thought some PO made a kind of shabby job replacing that piece of wire for some reason, but now I know I have no protection in the charging circuit. It’s certainly better to find that out through discussion on the board here than in some post conflagration investigation trying to figure out what happened! Saved by the board! ![]() So, next project is to redo with a proper fusible link. I’ll be soldering and shrink wrapping mine though. I figure as long as the other one lasted, I hopefully won’t be needing to do another anytime soon…
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1972 Chevy C-10, SWB, Fleet, 350/350, PS, PB, HEI, mostly stock, Survivor. ![]() |
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#25 |
Registered User
Join Date: Dec 2010
Location: Columbia, MO
Posts: 256
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Re: Truck Died Instantly - Electrical Smoke/Smell
**UPDATE**
Well, this is interesting. I wired in the new 16-ga fusible link this morning. Popped the battery back in and started to hear ticking over by the alternator and the same electrical smell as when this all started. Look over and the alternator is smoking! Yes, the battery was connected the correct way. Only one way to get the cables to reach and I can verify the negative ground to the block. I've attached two photos. First photo is self expalatory. Second is the red wire on the back of the alternator. Wondering if my alternator finally gave up the ghost after 15+ years? Smoke seemed to be coming from the alternator interior. Also, before doing any work I got on my creeper and checked all of the wiring I could. I see no evidence of roden damage. Thoughts? Time for a new alternator obviously but I wanted to post here first. This isn't my daily so I can take my time. Thanks as always!
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1972 GMC 2500 Custom, 96K miles, Purchased New By My Grandparents 2016 Toyota Tundra TRD Off-Road SR5 1993/2003/2005 Toyota Land Cruisers 2004 Corvette Z06 / 2000 Covette Coupe 2006 Ducati Multistrada 2014 BMW X3 XDrive35i M Sport |
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