Battery terminals melting, HELP PLEASE - The 1947 - Present Chevrolet & GMC Truck Message Board Network

mt Al · 05-02-2002, 09:10 AM

I bought a '72 suburban a few weeks ago and, no surprise, it has serious electrical problems.

I put in a battery a week ago and it went dead after a few days. I noticed that the positive terminal had actually melted partially and that the wire covering was partially melted.

Put in a new battery last night and noticed sparks coming from the positive terminal and smoke from the negative when I turned it over, quickly unhooked the battery and made an appointment with "the shop".

This morning I hooked it up again, it barely turned over and the negative terminal partially melted and the wire actually came out of the lead clamp!!

The grounding wire appeared OK, its hooked up to the AC clamp that is bolted to the intake manifold (now an Edlebrock Performer RPM).

Any suggestions? I just want to get it to the shop without having to tow it.

Thanks very much

------------------
'72 GMC 1/2T 4x4 pickup and
'72 GMC 3/4T 4x4 suburban.
(current)
past rides were: '70 Chev 2wd farm truck
'71 GMC 2wd 1/2T 402 nice!
'72 Chev 2wd 1/2T 396

71GMC_3/4T · 05-02-2002, 09:14 AM

Humongous current draw. Possibly a starter that has shorted windings or commutators.

bouncytruck · 05-02-2002, 09:58 AM

be careful with that battery. There have been several people blow their batteries up out in front of my parents auto parts store. They can cause some serious damage to you and your truck.

------------------
'69 K-5 Blazer - 350/TH350, 6" lift, 35" tires
Bothell, WA

bobs409 · 05-02-2002, 10:22 AM

It's possibly bad grounds. Remove, clean and reistall the ground wire that goes from the (-) terminal to the fender.

I had this same problem once. The batt cables were smoking and melting and it turned out to be the ground wire wasn't making good contact.

It's a good idea to clean all connections too.

------------------
63 Impala*66 Chevelle SS*69 Chevelle*69 C10 Stepside*71 Cheyenne 20*72 Chevelle

Parts for sale:
http://www.angelfire.com/trek/mr409/items4sale.html

mt Al · 05-02-2002, 10:40 AM

Ground to the fender? Are you talking about that light-guage wire?

My pickup is grounded to the dealer-installed AC bracket and this suburban is grounded to the intake manifold.

The starter was sounding funny.....

Thanks, and any other input would be appreciated.

BubbaGreen · 05-02-2002, 11:33 AM

After you get it running, check the voltage
at the battery terminals. It may be over-
voltage, ie, ext regulator bypassed or not
working, etc....also might want to have your
alternator tested off the truck, so to make
sure its working correctly.
Also, make sure you double check the big
connections at the starter and the engine
ground. Inspect the misc frame to cab,
frame to engine...etc grounding straps...
some might be missing or corroded.

------------------
71 Chevy C-10 SWB Fleetside WAS:307w/3-on-the-tree NOW:350TBI/700R4/3.73
See it at www.prismnet.com/~grzanich

**COBALT** · 05-02-2002, 11:43 AM

The negative side of the battery should go directly to ground (passenger side of the engine block, to a bare spot on the radiator support, or to an accessory bracket).

I had a similar problem when I tried swapping in a new battery into my parts truck. Turns out the + and - were swapped for some reason. I was putting the damn thing in backwards and didn't know it until I traced the "+" side of the battery, which turned out to be grounded!

lol

------------------
'69 3/4 ton C20 2wd w/ 350ci/400THM and a wood bed!
'69 3/4 ton Custom 20 2wd w/ ORIGINAL 350ci/4sp Manual and a wood bed (parts beast).
Seattle, WA.

*See pics of my trucks and project at www.webshots.com!

**CPNE** · 05-02-2002, 12:13 PM

Had similar problems. Turned out to be voltage regulator on the LH side of the rad support. I replaced starter and everything before I swapped in this $15 part. If your alternator is still externally regulated I'd start by replacing voltage reg.

------------------
Jeff Jesseman
Cheyenne Parts Northeast
Franconia, NH

67 Chevy SWB Fleetside
70 GMC Burb 1/2 ton 2wd
72 Chevy Burb 3/4 ton 4x4

Parts bought and sold

O'l Buck · 05-02-2002, 01:04 PM

any time i've had that problem it was always a bad ground either a bad wire, connection, clamp, or just plain dirty cable.

------------------
Ol' Buck: '72 Chevy 1/2T 4x4 shortbox stepside 350/350auto on '84
ralleys and 31/10.5s

Angel girl: 67 Cutlass convertible
330, 3spd stick

Greener: 90 GMC Jimmy
350/auto
Chad Stephens
Orleans,NE

no name yet: 72 442 under serious construction

mt Al · 05-02-2002, 02:40 PM

Thanks again for all the help. One more stupid question to add:

How do I tell if the alternator is internally regulated or external? It looks different from the internally regulated one in my pickup, but still has two wires coming out of the top, hooked up to the standard wiring harness. Also, the regulator doesn't have any jumpers.

Again, thanks a million. Wish I could help others as much as I've been helped.

Al

------------------
'72 GMC 1/2T 4x4 pickup and
'72 GMC 3/4T 4x4 suburban.
(current)
past rides were: '70 Chev 2wd farm truck
'71 GMC 2wd 1/2T 402 nice!
'72 Chev 2wd 1/2T 396

Gordo · 05-02-2002, 06:14 PM

Take note of the plug that inserts into alt., if it's rectangle in shape, it's internally regulated, if it's square it's external.

------------------
1971 C10 swb stepside 350/700R4/3.73posi
Killingworth, Connecticut

*Fast68Chevy* · 05-02-2002, 08:29 PM

i had the same thing happen a few times, the most recent time it completely melted the negatvie clamp off the battery, made a puddle of lead on the battery, i replaced cable and bolted it to block at waterpump and replaced both cable clamps and its good now.
its because of crappy dirty connections, clean them all or replave them and run ground cables from battery to body and body to frame

------------------
Randy- Lincoln, IL
randy@ccaonline.com 2177353230
*many GM parts bought, traded, or sold -am parting out: '81 Cutlass Supreme Brougham

current fleet: -71 C-10 350/CH465/3.07- basketcase
-84 Z28 5.0L/700R4/3.73 daily driver
-84 Firebird/SE 2.8L/T-5/3.73/engine bad
-82 purple Trans Am, project #2
*Paint is overrated*
© RSS Enterprises 2000

**KevsClassics** · 05-12-2009, 01:18 AM

I agree.

**El Jay** · 05-12-2009, 01:26 AM

Lordy!!!!!!!!!!

This is 7 years old!!!!
How did it come back??????

**special-K** · 05-12-2009, 06:31 AM

Hey Kev,what`s up with bringing up all these 7 year old posts?No offense,but,it sure is annoying.
I have an answer to the problem,but what`s the point?I guess we can still learn from it.But,it sure won`t help the guy with the problem,unless he`s still melting battery posts 7 years later.Some of us here like to help others with their problems and put thought and concern out to find an answer.It`s like a false alarm or crying "Wolf".

I`d suspect the battery ground to motor since it has an aluminum intake and would mount the ground directly to the block.Then,make sure the block is grounded to body at firewall and the body is grounded to frame.
It does sound like the starter is pulling to much draw,like fields are shot or other reason for excessive drag or draw.

Many members don`t even read the thread,just the original post,then reply.So,it`s darn annoying to see people answering 7 year old questions as if it`s today.And,it`s always you who brings them up.What`s up?I read old archives and have even brought some back because I felt they were as helpful now as then.But,I didn`t answer them like it was yesterday.I don`t know...just curious what you`re thinkin`,that`s all.

mrein3 · 05-12-2009, 07:27 AM

I think what is amazing about this thread from the dead is that it was responded to by none other than Randy - aka Fast68Chevy. He has been banned longer than most of us have been on the board.

**special-K** · 05-13-2009, 06:37 AM

Just a tad nutty,ain`t it?

Someone asks a question and gets answers.Seven years later someone posts,"I agree." That`s great to know.

05-02-2002, 09:10 AM	#1
mt Al Registered User Join Date: Aug 2001 Location: Bozeman, Montana Posts: 243	Battery terminals melting, HELP PLEASE I bought a '72 suburban a few weeks ago and, no surprise, it has serious electrical problems. I put in a battery a week ago and it went dead after a few days. I noticed that the positive terminal had actually melted partially and that the wire covering was partially melted. Put in a new battery last night and noticed sparks coming from the positive terminal and smoke from the negative when I turned it over, quickly unhooked the battery and made an appointment with "the shop". This morning I hooked it up again, it barely turned over and the negative terminal partially melted and the wire actually came out of the lead clamp!! The grounding wire appeared OK, its hooked up to the AC clamp that is bolted to the intake manifold (now an Edlebrock Performer RPM). Any suggestions? I just want to get it to the shop without having to tow it. Thanks very much ------------------ '72 GMC 1/2T 4x4 pickup and '72 GMC 3/4T 4x4 suburban. (current) past rides were: '70 Chev 2wd farm truck '71 GMC 2wd 1/2T 402 nice! '72 Chev 2wd 1/2T 396 __________________ '72 GMC 1/2T 4x4 1500 Super Custom pickup (current) past rides were: '70 Chev 2wd farm truck '71 GMC 2wd 1/2T 402 nice! '72 Chev 2wd 1/2T 396 '72 GMC 3/4T 4x4 2500 Super Custom suburban. Bozeman, Montana

05-02-2002, 09:58 AM	#3
bouncytruck SKINNY TIRES RULE! Join Date: Sep 2001 Location: Bothell, WA Posts: 11,038	be careful with that battery. There have been several people blow their batteries up out in front of my parents auto parts store. They can cause some serious damage to you and your truck. ------------------ '69 K-5 Blazer - 350/TH350, 6" lift, 35" tires Bothell, WA __________________ bouncytruck 1972 K5 The Hauler 1994 K1500 Suburban The Daily2010 Kia Soul Wife's Ride2014 Fiat 500L

05-02-2002, 10:22 AM	#4
bobs409 1969 Custom 30 wrecker Join Date: Sep 2001 Location: Pottsville, Pa Posts: 2,611	It's possibly bad grounds. Remove, clean and reistall the ground wire that goes from the (-) terminal to the fender. I had this same problem once. The batt cables were smoking and melting and it turned out to be the ground wire wasn't making good contact. It's a good idea to clean all connections too. ------------------ 63 Impala66 Chevelle SS69 Chevelle69 C10 Stepside71 Cheyenne 20*72 Chevelle Parts for sale: http://www.angelfire.com/trek/mr409/items4sale.html __________________ Bob 63 Impala 283/PG/3.36 (under restoration) 66 Impala 327/PG/3.36 66 Chevelle SS 409/M22/3.55 69 Chevelle 307/PG/3.08 (future restoration) 69 C10 short stepside 454/TH350/3.73 69 Custom 30 tow truck 350/4 spd/4.10 (resto done, CRUISIN TIME!) 71 Cheyenne 20 fleetside 350/4 spd/4.10 71 Chevelle 6/PG/3.08 72 Chevelle 454/M21/4.10

05-02-2002, 10:40 AM	#5
mt Al Registered User Join Date: Aug 2001 Location: Bozeman, Montana Posts: 243	Ground to the fender? Are you talking about that light-guage wire? My pickup is grounded to the dealer-installed AC bracket and this suburban is grounded to the intake manifold. The starter was sounding funny..... Thanks, and any other input would be appreciated. __________________ '72 GMC 1/2T 4x4 1500 Super Custom pickup (current) past rides were: '70 Chev 2wd farm truck '71 GMC 2wd 1/2T 402 nice! '72 Chev 2wd 1/2T 396 '72 GMC 3/4T 4x4 2500 Super Custom suburban. Bozeman, Montana

05-02-2002, 11:33 AM	#6
BubbaGreen Senior Member Join Date: Mar 2001 Location: Cedar Park, TX Posts: 686	After you get it running, check the voltage at the battery terminals. It may be over- voltage, ie, ext regulator bypassed or not working, etc....also might want to have your alternator tested off the truck, so to make sure its working correctly. Also, make sure you double check the big connections at the starter and the engine ground. Inspect the misc frame to cab, frame to engine...etc grounding straps... some might be missing or corroded. ------------------ 71 Chevy C-10 SWB Fleetside WAS:307w/3-on-the-tree NOW:350TBI/700R4/3.73 See it at www.prismnet.com/~grzanich __________________ 71 Chevy C-10 SWB Fleetside RamJet-350/4L60e & Compushift/3.73Posi See it at www.prismnet.com/~grzanich

05-02-2002, 09:14 AM	#2
71GMC_3/4T Weapons Of Construction Join Date: Apr 2000 Location: Colorado, USA Posts: 1,095	Humongous current draw. Possibly a starter that has shorted windings or commutators. __________________ 1971 GMC 2500, 402/TH400 4.10 Daily Driver Lafayette, CO

05-02-2002, 11:43 AM	#7
COBALT Senior Member Join Date: Sep 2001 Location: Seattle, WA, USA Posts: 5,817	The negative side of the battery should go directly to ground (passenger side of the engine block, to a bare spot on the radiator support, or to an accessory bracket). I had a similar problem when I tried swapping in a new battery into my parts truck. Turns out the + and - were swapped for some reason. I was putting the damn thing in backwards and didn't know it until I traced the "+" side of the battery, which turned out to be grounded! lol ------------------ '69 3/4 ton C20 2wd w/ 350ci/400THM and a wood bed! '69 3/4 ton Custom 20 2wd w/ ORIGINAL 350ci/4sp Manual and a wood bed (parts beast). Seattle, WA. *See pics of my trucks and project at www.webshots.com! __________________ '69 3/4 ton C20 2wd-350ci/TH400 '69 3/4 ton Custom 20 2wd-350ci/4sp Manual '99 2wd 5.7 Chevy Tahoe Seattle, WA.

05-02-2002, 12:13 PM	#8
CPNE Resident Curmudgeon Join Date: Dec 1999 Location: NH Posts: 6,662	Had similar problems. Turned out to be voltage regulator on the LH side of the rad support. I replaced starter and everything before I swapped in this $15 part. If your alternator is still externally regulated I'd start by replacing voltage reg. ------------------ Jeff Jesseman Cheyenne Parts Northeast Franconia, NH 67 Chevy SWB Fleetside 70 GMC Burb 1/2 ton 2wd 72 Chevy Burb 3/4 ton 4x4 Parts bought and sold __________________ Currently on or near the homestead: 67 Chevy SWB 2WD stepside 350/3 on tree (Pat's) 67 GMC SWB 2WD Fleet 402/auto (Brian's under construction) 67 Chevy 3/4 ton 2WD 402/auto (Business Hauler) 67 Chevy 1 ton dually 2WD 396/4 speed (Former business hauler, Needs TLC) 68 Chevy 1/2 ton Suburban 2WD 250 six/3 on tree (Brian's Needs TLC) 70 Chevy 3/4 ton 4WD 350/4 speed (Pat's - Disguised as a 68 GMC) 71 Chevy SWB stepside (Crushed by tree - parts donor) 72 Chevy 3/4 ton 4WD (Parts donor) 72 Chevy 3/4 ton 4WD Suburban (Parts Donor) 72 GMC 3/4 ton 4WD 292 six/4 speed (Mine - Disguised as a 67 GMC) 81 GMC 4WD Dually Dump Body 350/4 speed (Business Hauler) 82 Camaro Z/28 355/Super T-10 (Pat's toy) 93 Caprice 9C1 (Brian's Cop Car) 02 Toyota Camry (Reliable but a souless steel and plastic hulk) 2011 2SS RS Camaro M6 Factory Hurst Shifter Maybe I need to sell some of this crap Yet another Bozo with a sawz-all

05-02-2002, 01:04 PM	#9
O'l Buck Recovering Truck Driver Join Date: Mar 2002 Location: Orleans, NE USA Posts: 1,883	any time i've had that problem it was always a bad ground either a bad wire, connection, clamp, or just plain dirty cable. ------------------ Ol' Buck: '72 Chevy 1/2T 4x4 shortbox stepside 350/350auto on '84 ralleys and 31/10.5s Angel girl: 67 Cutlass convertible 330, 3spd stick Greener: 90 GMC Jimmy 350/auto Chad Stephens Orleans,NE no name yet: 72 442 under serious construction __________________ 67 K-20 350, SM465, Eaton rear, 4.56 no spin option 00 Dodge 2500 4x4, 24V cummins, 5 speed Chad South Central Nebraska

05-02-2002, 02:40 PM	#10
mt Al Registered User Join Date: Aug 2001 Location: Bozeman, Montana Posts: 243	Thanks again for all the help. One more stupid question to add: How do I tell if the alternator is internally regulated or external? It looks different from the internally regulated one in my pickup, but still has two wires coming out of the top, hooked up to the standard wiring harness. Also, the regulator doesn't have any jumpers. Again, thanks a million. Wish I could help others as much as I've been helped. Al ------------------ '72 GMC 1/2T 4x4 pickup and '72 GMC 3/4T 4x4 suburban. (current) past rides were: '70 Chev 2wd farm truck '71 GMC 2wd 1/2T 402 nice! '72 Chev 2wd 1/2T 396 __________________ '72 GMC 1/2T 4x4 1500 Super Custom pickup (current) past rides were: '70 Chev 2wd farm truck '71 GMC 2wd 1/2T 402 nice! '72 Chev 2wd 1/2T 396 '72 GMC 3/4T 4x4 2500 Super Custom suburban. Bozeman, Montana

05-02-2002, 06:14 PM	#11
Gordo Registered User Join Date: Jan 2001 Location: Killingworth, CT. USA Posts: 3,378	Take note of the plug that inserts into alt., if it's rectangle in shape, it's internally regulated, if it's square it's external. ------------------ 1971 C10 swb stepside 350/700R4/3.73posi Killingworth, Connecticut __________________ 1971 C10 swb stepside 350/700R4/3.73posi (retired as of 4/22/03) 1998 S10 short bed 2002 S10 Blazer 1942 Oldsmobile 1958 Massey Harris Pony 1951 Wife Killingworth, Connecticut May those who love us, love us, any of those who do not love us, may God turn their hearts. And if God is unable to turn their hearts, may he turn their ankles so we may know them by their limping. A man who works with his hands is a laborer; a man who works with his hands and his brain is a craftsman; but a man who works with his hands and his brain and his heart is an artist.

05-02-2002, 08:29 PM	#12
Fast68Chevy Account Suspended Join Date: May 2000 Location: IL Posts: 0	i had the same thing happen a few times, the most recent time it completely melted the negatvie clamp off the battery, made a puddle of lead on the battery, i replaced cable and bolted it to block at waterpump and replaced both cable clamps and its good now. its because of crappy dirty connections, clean them all or replave them and run ground cables from battery to body and body to frame ------------------ Randy- Lincoln, IL randy@ccaonline.com 2177353230 many GM parts bought, traded, or sold -am parting out: '81 Cutlass Supreme Brougham current fleet: -71 C-10 350/CH465/3.07- basketcase -84 Z28 5.0L/700R4/3.73 daily driver -84 Firebird/SE 2.8L/T-5/3.73/engine bad -82 purple Trans Am, project #2 Paint is overrated* © RSS Enterprises 2000

05-12-2009, 01:18 AM	#13
KevsClassics TILT COLUMN GURU Join Date: Dec 2006 Location: FRESNO CA Posts: 4,276	Re: Battery terminals melting, HELP PLEASE I agree. __________________ Instagram kevs_classics64 64 Impala SS Conv 72 Blazer 2wd 75 Jimmy 2wd 63 Belair wagon 02 Silverado ext cab. DD RIP EL JAY

05-12-2009, 01:26 AM	#14
El Jay Gone to greener pastures Join Date: May 2007 Location: Gateway to the Delta Posts: 7,354	Re: Battery terminals melting, HELP PLEASE Lordy!!!!!!!!!! This is 7 years old!!!! How did it come back?????? __________________ '69 Chevy 1/2 T LWB Stepper: Daily Beater '72 GMC 3/4 T Fleet: Another Daily Beater '72 Plymouth Gran Coupe: ? "Ah women. They make the highs higher and the lows more frequent." Friedrich Nietzsche "Never kick a fresh turd on a hot day." Harry S. Truman GUN CONTROL: Never having to say, "I missed you." Always fire two warning shots into your attacker's chest area before putting a bullet between his eyes. Paraphrased from Louis Awerbuck

05-12-2009, 06:31 AM	#15
special-K Special Order Join Date: Nov 2004 Location: Mt Airy, MD Posts: 85,851	Re: Battery terminals melting, HELP PLEASE Hey Kev,what`s up with bringing up all these 7 year old posts?No offense,but,it sure is annoying. I have an answer to the problem,but what`s the point?I guess we can still learn from it.But,it sure won`t help the guy with the problem,unless he`s still melting battery posts 7 years later.Some of us here like to help others with their problems and put thought and concern out to find an answer.It`s like a false alarm or crying "Wolf". I`d suspect the battery ground to motor since it has an aluminum intake and would mount the ground directly to the block.Then,make sure the block is grounded to body at firewall and the body is grounded to frame. It does sound like the starter is pulling to much draw,like fields are shot or other reason for excessive drag or draw. Many members don`t even read the thread,just the original post,then reply.So,it`s darn annoying to see people answering 7 year old questions as if it`s today.And,it`s always you who brings them up.What`s up?I read old archives and have even brought some back because I felt they were as helpful now as then.But,I didn`t answer them like it was yesterday.I don`t know...just curious what you`re thinkin`,that`s all. __________________ "BUILDING A BETTER WAY TO SERVE THE USA"......67/72......"The New Breed" GMC '67 C1500 Wideside Super Custom SWB: 327/M22/3.42 posi.........."The '67" (project) GMC '72 K2500 Wideside Sierra Custom Camper: 350/TH350/4.10 Power-Lok..."The '72" (rolling) Tim "Don't call me a redneck. I'm a rough cut country gentleman" R.I.P. ~ East Side Low Life ~ El Jay ~ 72BLUZ ~ Fasteddie69 ~ Ron586 ~ 67ChevyRedneck ~ Grumpy Old Man ~ Last edited by special-K; 05-12-2009 at 06:36 AM.



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05-12-2009, 07:27 AM	#16
mrein3 Registered User Join Date: Feb 2000 Location: Center City, MN, USA Posts: 3,254	Re: Battery terminals melting, HELP PLEASE I think what is amazing about this thread from the dead is that it was responded to by none other than Randy - aka Fast68Chevy. He has been banned longer than most of us have been on the board. __________________ '70 cab, '71 chassis, 383, TH350, NP205. '71 Malibu convertible '72 Malibu hard top Center City, MN

05-13-2009, 06:37 AM	#17
special-K Special Order Join Date: Nov 2004 Location: Mt Airy, MD Posts: 85,851	Re: Battery terminals melting, HELP PLEASE Just a tad nutty,ain`t it? Someone asks a question and gets answers.Seven years later someone posts,"I agree." That`s great to know. __________________ "BUILDING A BETTER WAY TO SERVE THE USA"......67/72......"The New Breed" GMC '67 C1500 Wideside Super Custom SWB: 327/M22/3.42 posi.........."The '67" (project) GMC '72 K2500 Wideside Sierra Custom Camper: 350/TH350/4.10 Power-Lok..."The '72" (rolling) Tim "Don't call me a redneck. I'm a rough cut country gentleman" R.I.P. ~ East Side Low Life ~ El Jay ~ 72BLUZ ~ Fasteddie69 ~ Ron586 ~ 67ChevyRedneck ~ Grumpy Old Man ~

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