The alternator side

 

What size Is the fuse? If it's 150a. Try going down to 125a

 

It's whatever the kit comes with, but why would the fuse be the issue? The alternator doesn't even put out 100 Amps I don't think. There haven't been any charging system upgrades or anything other than these wires and the alternator in it puts out less than what my Cherokee came with from the factory.

 

Where do you have it mounted at? Haven't had any issues with mine. I have it mounted between the washer bottle and PDC on mine....

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I know the washer bottle on the newer ones like yours is in the driver's side fender though, so I'm not sure what you have in that spot on yours.

 

 

Did the little plastic button fall out of the bottom of the fuseholder and then the bolt shorted out against something?

 

No. I thought it was a possibility the first time, but I made sure to super glue these in before putting it all in.

 

How many times did you replace the fuseholder

 

I had the original one you gave me, I posted the picture here when it melted, you said the cap probably fell off the bottom so I just accepted it, ordered a two pack of them because I figured i could always use another for something. Put superglue on the caps and installed it, that one is the one that just melted, now I put a new one in yesterday which would be number 3. So 2 have melted, onto the 3rd but hoping it doesn't melt.

 

Did you ever replace your alternator?

 

It was replaced September 25, 2016. All they had in stock was a lower output than factory, but I needed one so I got it. I don't remember exactly what the output is but I believe it's in the 90 amp range.

 

Sound like a loose connection. Double check with connections on each cable in the jeep.

 

There has to be something wrong with the system for it to heat up. My son had a loose connection on the front of the fuse and relay box and melted it down. at least that is what we thought caused the melt down. He had to take the one from our parts jeep and re-wire the box. We also think his extreme stereo system may have caused the melt down not sure.

But a loose connection will cause things to heat up from arcing

 

I just sent you an email.

 

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