Hi everyone,
Brief summary of what's been happening:
I blew my motor up the beginning of the year and I have swapped it out recently and have been trying to get everything hooked back up again so I can have my jeep back but this last issue has been a pain for me!!!

I keep blowing both 60amp Alt Power fuses and I cannot figure out why. I have gone through and checked all my wires from my alternator, my battery, fuses, wiring harness, all my grounds and I cannot find any reason why it would be blowing. I have done resistance tests on all connections that I can to see if there is a wire causing the issue and I can't find anything. The fuses only blow as soon as I hook the battery up or as soon as I set a fuse in if the battery cables are attached already. Any ideas as to what could be causing this? PLEASE HELP!

 

have you used an ohm meter to check all the loads to ground? I would disconnect the positive cable from the battery and hook the meter between it and ground. You should see a short with the fuse installed. I would then start disconnecting each load while watching the meter.If the short is still there after disconnecting all the loads then it's most likely in the wiring

 

I thought that I had done that by checking each individual wire with checking the resistance, unless I'm wrong? I can try testing that next. If for some reason its not shorting out with load wires connected, where can I try looking?

 

When you say Alt power I assume you mean alternator power. Have you disconnected the alternator and tried starting the rig?

 

Yes, I’ll take a picture of the fuses I’m talking about when I get home. I have not tried to start it with the alternator disconnected. I can do that as well when I get home

 

I forgot I had these. This is the fuse slot

These are the ones that are blowing

 

On a side note, you might want to check that green wire below the fuse block that looks like it's insulation is melted.

 

I just fired the jeep up without the alternator being connected, I haven't done the electrical tests yet. The green wire that you are talking about has some tape on it from the wires being all tied together. All the wires I have traced back to the ECU and they all look good.

 

I think this is the wire that’s causing the issues

So I think that wire that’s what’s causing the issues. I went through and read tighten all the grounds down and made sure I had everything connected just right. I put two brand new fuses in and then reconnected the negative terminal on the battery and after about a second and a half the fuse blew and I happened to fee the wire and it was hot. So I disconnected this wire and placed two new fuses in and reconnected the negative terminal and all is fine. What is this wire too?? Is that the fusable link? I checked the resistance and it shows zero but it concerns me that it’s so hot which would indicate a short if I’m not mistaken.

 

Late to the game but if the problem started after the engine install, look for a wire that you may have pinched or worn through the insulation during the install. The alternator might also have an internal short.

 

I thought that it was the alternator but it is still happening even with it being completely disconnected and it only happens when the battery ground is being hooked on. In the last picture, that wire got really hot when the last fuse blew, it only got hot from where the connecter is at to where I had it ground out at the bracket below the ignition coil. I think it may be that wire that has the issue. I've checked all the wires visually from the fuse bank under the hood all the way to the ECU.