97 TJ alternator won't charge battery and dies while idling

Samuel Orr

Samuel Orr

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Joined
Sep 8, 2022
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North Carolina
I’ve checked the alternator and battery, they’re fine. Voltage regulator is also reading fine. I went digging for wires and found a green cable connected to the side of the fuse box (next to battery), cut open and melted. This connects from the battery to the alternator from what I see. Believe it transfers the electricity. I need to replace this green cable, does anyone know what it’s called or what I need to ask for at the auto store? I’m inexperienced with automotive tech.

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The wire between the alternator and fuse box has a fusible link. Fusible links are a short piece of wire that is 1 or 2 sizes smaller than the main wire, and has special insulation. In an over current situation the smaller length of wire melts itself to break the connection.

You can see in your first pic it says "fuse link" on the wire insulation. If that's the piece that melted you have a problem somewhere. Replacing it with a normal piece of wire is a bad idea. You should replace it with another fusible link.
 
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I don't recall ever seeing a fusible link in a 1997 TJ charging system. 🤔 that pic shows yes a fused wire and a aftermarket quick spice style connector.
 
So I searched and looked at a wiring diagram. Sure enough there is a fusible link in line from the alternator to the BJB. I didn't know that. Neato!

Anyways like said above me. Replace with same rated link or risk it all. 🔥
 
freeskier93 said:
The wire between the alternator and fuse box has a fusible link. Fusible links are a short piece of wire that is 1 or 2 sizes smaller than the main wire, and has special insulation. In an over current situation the smaller length of wire melts itself to break the connection.

You can see in your first pic it says "fuse link" on the wire insulation. If that's the piece that melted you have a problem somewhere. Replacing it with a normal piece of wire is a bad idea. You should replace it with another fusible link.
Click to expand...

Ah I see. Nobody currently uses this jeep at all. I was hoping to replace the entire wiring system sometime soon, but I needed this fixed very quickly so that I can complete my next project. Just low power activities. When I’m done I’ll be sure to install the proper cables. Thanks bro
 
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