Melted pos. Battery clamp

[Pj beals]

I have 2006 5.9 the pos. Battery clamp melted off yesterday i replaced it but when i go to put the wire that goes to the solenoid behind the battery, it keeps sparkin and getting really hot. Any ideas

 

[dieselshadow]

You have a dead short (or very close) somewhere. Should be very easy to troubleshoot since you know what wire is causing it.

 

[Pj beals]

You have a dead short (or very close) somewhere. Should be very easy to troubleshoot since you know what wire is causing it.

So u dont think the solenoid may be bad? Idk didnt have much luck finding a short but will try again. My mechanic skills are pretty limited. Lol

 

[EDankievitch]

That relay sounds like it has failed in the closed position. I wonder if you have something grounding out your intake heater. I know there have been a few that the bolt comes loose inside and shorts things out. Worth checking

 

[DavidC]

If the wire is getting hot the device is drawing to many amps for the wire size either from a short or low resistance of the device. Could be some shorted windings in the solenoid lowering the resistance it is suppose to have. What is the solenoid for ?.

 

[seafish]

The grid heater solenoids can and do fail in the closed position.
You can get new ones from genos garage and replace them as necessary.

Alternatively, you can also simply not reconnect the wire to them as they are NOT needed to get the truck started except perhaps in EXTREME cold conditions. For example, mine have been disconnected on my truck for many years now and it always starts even in in sub freezing weather.

 

[Pj beals]

Thanks guys for the input.

 

[EDankievitch]

The few threads on here about the Grid heater failing, I would open up the intake and inspect it to make sure something is not about to come off and go through your engine.

 

[seafish]

Certainly your idea of deeper inspections for wiring or ground faults is a good idea, but I have never heard of grid heaters failing and falling into the engine on the 5.9 ISB that the OP has.

That said, on the newer designed grid heaters on the 6.7, there have in fact been a few issues with a certain bolt coming loose and potentially causing rapid additional engine carnage, but on the 5.9, I don't think so

Please do correct me or point me int he direction of these older failures if I am wrong!!!