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Starter fried after alternator/ alternator harness install

Hey folks,

A few days ago I upgraded to a 100 amp denso alt in my '93 240. While I was at it I rerouted the oil pressure and alt idiot light wires, as is sometimes recommended, and I switched out the crusty harness to the starter and the stubby ground wire to the engine block with new 4 gauge wire. The change was dramatic mostly i think because of the cracked and exposed state of the ground harness. With a warm running engine with no ac, lights, stereo, etc. I was getting a reading of about 14.15 volts at the battery at the battery. With ac, headlights, fogs burning I was getting 13.40 to 55 or something. But then a couple of days later, my starter solenoid stopped functioning leaving me stranded. My question: was the bump up to the 4 gauge wiring the reason for my starter woes? I don't know why it would be. The battery when engine is off was holding at about 12.50 volts. But I do not want to have to have to change out the starter again anytime soon. Those are a couple of rough bolts. Thanks in advance... William.








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    Starter fried after alternator/ alternator harness install

    I agree that the larger-gauge cable shouldn't have anything to do with the starter failing.

    Anytime you start messing with old wiring, you may bump something that was hanging on by a thread and break a connection. Maybe while you were working, something was knocked loose at the starter connections, including a ground. I'd check all connections at and to the starter first.

    Was the alternator tested before it was installed? Even new ones can be bad.








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      Starter fried after alternator/ alternator harness install

      Thanks for all the input. it was helpful.

      As you both suggested, the failing solenoid was unrelated to my alt/wiring harness upgrade. The age of the old starter is unknown, but it looked rather weary upon removal. All the wiring checked out, no weirdness could be detected. Alternator runs beautifully; steady consistent voltage at battery. I hope I never have to change a starter again. I had to seek assistance in order to get that top bolt out.

      Thanks again,
      William








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    Starter fried after alternator/ alternator harness install

    4 gauge wire had nothing to do with it. New, used, rebuilt alternator?
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