Ok..I've searched this whole site, but cannot find the answer...How does the positive battery cable connect to the lead that goes to the power distribution center. The cable on my wifes intrepid corroded and broke right where the cable connects to the short wire coming out of the power distribution center.
Don't have a picture as it happend last night. She said the car just died..no electrical whatsoever..Drove to where she was and tried to jump...no electrical even with jumper cables attached. Started cleaning the terminals and noticed where th positive cable goes to the PDC it was corroded. There is a about a 4" long wire (1/4" dia) that comes out of the PDC and goes to the pos terminal. The there is the other part of the pos cable that goes to the starter. There is a short (1/2' section) of the cable that goes to the PDC that is bare (probably the fusible link)..That is where the wire corroded abd broke...I'm goin to attempt to clean the two ends and put the wire back together so I can at least get the car home (only about a mile away). I did see some pics of replacment cables on O'reilly's web site showing and inline connector..I'll stop at Advance and see what they have. My concern was that this cable seemed to be 1 piece, but from what i am seeing in replacement parts is something that could be crimped. I believe that these are the original cables (~200K miles)
Yea, it could be a replacement cable on it that has pulled apart, or something strange may have happened that the fuseable link came apart - Just for safety sake, with the keys out of the ignition and the doors closed (dome light would be off normally), take VOM and measure current flow between the broken sections... if it is very high, you've got some sort of internal failure in a component and we'll have to figure out where... but yes, you can likely just crimp the two ends together and get it home.
I wouldn't go getting a new battery cable end, not yet... I'd get some bit crimps and try that first. In a pinch, a wire nut would also work.
I think the fusible link just corroded and that there was enough corrosion to impede current flow..Thanks for the tip in checking voltage..Next post will be a pic of the failure mode...Look for it in a few hours..
Here are the pic's I promised showing where the fusible link corroded..Ended up cleaning it all up, and cleaning post connectors. Then soldering the fusible link back together..Still had some good copper and connector to work with.
Wowsers. Need some serious wire brush action (might even want to use a sharp knife and SCRAPE* the battery posts) and some vaseline, in addition to a new fuseable link.
I'd also look for corrosion starting to take hold in the bottom of the power distriubtion box**.
*My 95 Dodge Spirit developed an intermittent no-start condition. I discovered a weird kind of BLACK or charcoal gray varnish-like coating had developed on my battery posts which a wire battery post cleaning brush wouldn't touch. I scraped the terminals all the way around longitudinally with the terminal, until they were bright, but I tried to avoid taking off too much lead because you can only crank those battery terminals down so far.
**My 2002 Grand Caravan recently had corrosion migrate as far as the front end of the power distribution block and compromise the ABS fuse, which is the frontmost fuse in the box. The weird thing is, I have had very little corrosion/battery leakage detected on my battery over the years. I tend to keep it pretty clean. It may be that the airflow characteristics under the edge of the hood/over the top of the headlight tend to blow corrosive residue from the battery back just right so it enters and contaminates the PDC, not sure if the same would apply to the Intrepid, but it looks to me like you've had some serious leakage there that likely has gone other places.