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negative battery cable gets hot.
02-13-2016, 06:08 AM
Post: #1
negative battery cable gets hot.
Hi again autowebrepair. So I am having problems with my 2002 Mercury Sable GS with the Vulcan 3.0L OHV and the AX4S automatic transmission. So about a month ago my original transmission of 255k lost reverse then it completely lost the everything. So I got it into my shop, got it all out and then one with only 170k on it back in. Had no problems what so ever. I have only 18 days of warranty left on the transmission just so everyone knows so I need help fast. So after getting everything installed correctly again I go to start it and it doesn't start, it just constantly clicks from the starter gear shooting out. So I pop the hood and look under it while I try to start it. The negative cable is bouncing, sparking, melting the wires at the tips of the copper, and even a couple of times shot the negative wires completely off, also just so you know this only happens when I turn the key over to start the car (which it won't start or turn over just the starter motor moving) and also this only happens to the negative battery cables to the battery. So I talk to a personal friend who has been a mechanic his whole life just about and he tells me it sounds like it is a ground problem, so I check all of my grounds and as far as I could tell they are solid (I pulled on them just a little to make sure they are held really good). But the connectors to the battery didn't look good so I went ahead and got NEW heavy duty connectors which made the connections to the battery solid. I try to start it and nothing, still won't start just the starter motor shooting over to turn the motor but it doesn't. So I don't know what to do but I need help. So any suggestions?
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02-13-2016, 07:48 AM (This post was last modified: 02-13-2016 07:49 AM by Garner.)
Post: #2
RE: negative battery cable gets hot.
There's a lot that "Could" be going on here. I'm not completely sure of what you are explaining so I will hit on several things for you to look at.

If the starter is spinning without turning the motor: Make sure that the teeth are on the starter gear. Make sure that the teeth are on the Torque Converter or Flex Plate. Since I can't remember if that unit has the teeth on the Torque or the Flex Plate, check to see if it is a Flex Plate. If it is, they can break out around the bolt holes. Is the Bendix actually kicking the starter gear into place? If the gear doesn't fly forward and contact the mating teeth, the starter will just spin without turning the motor. Can the motor be turned over manually? In other words, is the motor locked up.

Please let us know what you find.

Thanks for using the forum,
Garner

Interested in Mining? Look here: Coal Mining, PA
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02-13-2016, 12:15 PM
Post: #3
RE: negative battery cable gets hot.
That's the same point I was going to make. IOW, if the torque converter was not lined up properly in the front pump of the trany and you tightened the bolts anyway, perhaps everything is too tight for the starter to turn? Of course if that were the case you couldn't turn the engine to line up the converter bolts... unless you left the old converter connected to the flywheel during the swap, which is not the right way to do it.
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02-13-2016, 12:22 PM (This post was last modified: 02-13-2016 12:24 PM by nathaniel1995.)
Post: #4
RE: negative battery cable gets hot.
Yes I can turn the engine at the crank.

I got the transmission from buddy's-u-pull and I put a brand new pan and torque converter.
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02-13-2016, 03:33 PM
Post: #5
RE: negative battery cable gets hot.
Hot cables can only mean a few things:

High draw (bad starter or stuck engine / trany)

Bad connections (the cable ends or the contact points of the battery / block)

If you know the battery is good (or borrowed from another vevicle) you can do a simple test with a volt meter. Read battery voltage at the battery itself and a high draw situation will make the voltage drop, likely below 10 volts. A low draw with poor connections will be well above 11 volts and the bad connection will get warm.

Now, the warm connection could be the crimped end has the poor connection to the cable itself, in which case it may be easiest to just replace the entire cable. Make sure you buy a heavy enough cable. Guessing it will be at least a #4 and possibly a #2 gauge to take the starter draw. Also be sure youu have a good ground to the body from that negative terminal, which is likely another wire.
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02-13-2016, 03:45 PM
Post: #6
RE: negative battery cable gets hot.
Okay so starter is bad I will post after switching it out. Also so you can tell people ford is the only place that sells the internal wiring harness for the AX4S transmission but it isn't the correct length so just make sure they sell you one that is long enough.
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02-13-2016, 07:43 PM
Post: #7
RE: negative battery cable gets hot.
Okay so it was the starter.
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02-13-2016, 07:47 PM
Post: #8
RE: negative battery cable gets hot.
Funny how other stuff breaks in the middle of a project and confuses everything.

Happy Motoring!
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02-13-2016, 09:11 PM
Post: #9
RE: negative battery cable gets hot.
Glad to hear that you got it fixed. Thanks for taking the time to let us know! Not many people do that for us.

Visit us any time you need help.

Thanks for using the forum,
Garner

Interested in Mining? Look here: Coal Mining, PA
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02-14-2016, 11:43 PM
Post: #10
RE: negative battery cable gets hot.
Yea I know they don't so I did. I had to replace the end connectors going to battery and starter. Now I have a new problem but gonna start a new thread so people in need can find it sooner.
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