I have a new alternator that is already showing signs of rust on the screws as well as other parts on the engine. Now, I have been having discharging problems over night as well as an issue with consistant eletrical flow - sometimes the car has no power and sometimes it does, all randomly. I might have to wiggle the battery connection sometimes to restore it.

With this new rust though it is making me think that there is either a serious grounding issue or something is shorting out. Any thoughts?

 

First, you bump has been deleted. Bumps are forbidden in the 2nd gen technical section.

#2 If you have to wiggle a wire to make something work, you have a bad connection. Pretty cut and dry there. Fix the joint where you have to wiggle

#3 after that is repaired, you need to do a current draw test to see what the idle draw is in the vehicle. This has been covered quite a few times here, but you will need a multi- meter (preferably digital) to check the draw.

 

Sorry, haven't posted in...5 months?

I'm familiar with both #2 and #3. The battery is relocated so I have no doubt that there might be an issue there with the loose connection. I plan on rewiring it again with no remote terminals this time.

I just want to know what causes the rust so dramatically. It's actually jutting off of a screw on the alternator casing which is I believe is not normal. Only thing I can think of is some sort of current(DC?) running through the grounds and accelerating oxidation?

 

yep, and a current draw test would show that.

Also, as far as build up at the battery itself. It is not uncommon to have a battery that someone overtightened the clamps, to distort the post enough to cause a battery to leak.

So if the clamps were overtightened, the battery would leak vapor causing accellerated rusting, but if you have located the battery in the rear you can rule that out. Then I would be looking at missing some of the hood seals. Missing front and rear hood seals lets way too much moisture in when driving in poor weather.

 

Thanks. I will do a current test on the engine. The battery drain started a little bit after I relocated it in the pass. bin, and since I can't see the wires that run under the carpeting I don't know if they are exposed or not.