Got a '92 244 with a bad alternator. Replaced it, reconnected all wires properly at the alternator. Put negative battery cable on the negative battery post, sparks from the negative battery cable and the ground wire was smoking. Ground wire insulation was destroyed.

Alt is a rebuilt Bosch, battery is good and fully charged.

Do I need a larger gauge ground wire from the engine block to the alt? Any other items to check? I've replaced multiple alternators before and have never had this.

Thanks

Positive alternator wire is touching alternator case.

I'll ask the obvious but where exactly did you connect the ground wire on the alternator?
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Post Back. That's whats makes this forum work.

Yep...you have a dead short to an unfused battery circuit. Only two possibilities:

Ground wire is attached to the wrong location.
Alterator is defective with a dead short to the case.

Thanks for the answers. The Bosch rebuilt purchased from IPD tested bad. I have ordered another alt from Napa and it will be here tomorrow afternoon. I apopreciate the assistance.

You gonna return the alt too IPD?
Returns keeps their pats straight

IPD was very responsive. They emailed a shipping label and I dropped it off with FedEx this morning. T%hey won't reverse the credit card charge until they receive the alternator. So far, so good.