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post #1 of 12 (permalink) Old 04-10-2019, 11:28 AM Thread Starter
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Main Battery Connection Cable

As I was getting my 1991 Spider ready for spring, I discovered that the jacketing on the main battery connection cable that runs across the back of the engine compartment has melted away. Can anyone advise on the difficulty and process of replacing that cable? It is a continuous cable that runs from the trunk, under the car, and across the engine compartment? Thanks, John.
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post #2 of 12 (permalink) Old 04-11-2019, 09:16 AM
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Difficulty?

John,
difficulty is of course depending on the tools you have accessible to your use. Do you have a lift for the Alfa? You will need to get under the car. The cable runs underneath to back of passenger seat area and enters the interior at the "tray" area. Continues through the "interior-trunk" wall, into the trunk, to the battery. It is one continuous cable.
Cable is secured at different intervals under the chassis along-side with gas & brake lines.
GLW endeavor.
be sure of proper wire mil size.

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post #3 of 12 (permalink) Old 04-11-2019, 10:09 AM Thread Starter
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Fantastic! Thanks for the reply and constructive information. John.
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post #4 of 12 (permalink) Old 04-11-2019, 10:36 AM
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You can buy new primary copper cables with insulator jackets online, by the foot, but the question still is, why did it melt the insulation jacket? Is there something lurking in there still, to bite you? Starter or solenoid short out?
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post #5 of 12 (permalink) Old 04-11-2019, 10:42 AM Thread Starter
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I had to replace the alternator last year. The exposed wiring was green with oxidation. If the jacketing had melted by the time I replaced the alternator, I would have thought my mechanic would have said something.
post #6 of 12 (permalink) Old 04-11-2019, 03:53 PM
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Well, if you saw that kind of corrosion on the outside of the wiring and at terminals, you can bet it extended into the strands of copper wire, thus raising resistance and producing heat.

I'd suggest you have someone experienced in auto electrical systems do a voltage drop test on all your primary components... from the battery forward to the alternator, starter, and the junction block there on the fender where those red wires get distributed. You need to know the root cause of that kind of overheating, in my opinion. Maybe it was the corrosion, or maybe there's more to it.
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post #7 of 12 (permalink) Old 04-12-2019, 01:16 AM
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if the burned section of the cable is visible and doesn't actually disappear into the bulkhead, I'd look at professionally splicing in a new repair section with correct AWG wire.
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post #8 of 12 (permalink) Old 08-23-2019, 08:26 PM
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While this thread has been dormant for a while, I please ask: What is the correct AWG wire size for a 1991 Spider Veloce positive battery cable?
Thanks.
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post #9 of 12 (permalink) Old 08-23-2019, 09:11 PM
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Quote:
Originally Posted by clescn View Post
While this thread has been dormant for a while, I please ask: What is the correct AWG wire size for a 1991 Spider Veloce positive battery cable?
Thanks.
On my '91, it looks like 1/0 or 2/0 AWG cable, based on the diameter.

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post #10 of 12 (permalink) Old Yesterday, 03:15 PM
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Thank you. I'll probably go with 2/0 AWG cable.
The reason I'm asking, I'm replacing the positive cable from battery to starter. Would anyone know the size of the stud (8 mm or 9 mm?) on the solenoid to which the battery attaches?
My thanks in advance.
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post #11 of 12 (permalink) Old Yesterday, 03:29 PM
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Studs on starter solenoid are 8mm

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post #12 of 12 (permalink) Old Yesterday, 07:13 PM
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Thanks, Nakagtv.
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