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Alternator not charging, brand new alternator and battery, alternator harness had melted, where it plugs into the main harness changed both connectors car still runs off battery and all fuses appear to be good
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An alternator can run on two wires, the thick wire is the supply to charge the battery, direct to positive, via fuse box or starter supply. The thin wire possibly blue on Fords, is the energiser wire from the dash charge light, without this connected the alternator will not charge. If on the new pigtail two wires are thick (30amp) you can ignore one, some vehicles double up on the charge supply wire.
There should be a 100amp fuse in the box near the battery for the main circuit between the alternator and battery. The engine computer controls output. If the fuse has power you may need a shop to check the charging system.
A melted plug typically means a loose connection. Maybe one of the pins in the connector got loose and the poor connection created heat. If there are only a couple of wires to the plug and harness I would cut out the plugs and use good solderless connectors to repair. I wil be a lot less expensive than a new harness. If it is just damage to the plug going to the alt you can get replacements for them.
the alternator is still not charging be sure to check all the grounds on transmission and be sure the plug that goes into alternator is not melted or damaged you may have gotten a dud alternator some aftermarket rebuilds are **** please rate -jeff
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