[s-cars] Re[ps-cars] Burned battery cable

[Tom Green]

Wow, I think you dodged the bullet, Ron.  As recommended, I would
inspect the seat springs for any evidence of arcing and put some extra
plastic to isolate the positive post.  As Dave F. suggested, it is  
common
to see the wrong battery in the cars, probably from ignorance and a
quest for a cheap battery.  As you have witnessed, this is not a  
place to
skimp on quality.  Suppose the battery had generated a little  
hydrogen gas
at this time.  I would not have wanted to be a back seat  
passenger.  : > )

If the battery failed internally, it probably would have done more  
damage
to the case, perhaps exploding, and not produce enough voltage to start
the car.  I don't think a loose connection would cause the damage.

It is possible that corrosion in the cable can cause enough  
resistance to
heat up the cable enough to char the insulation, but regardless, you  
need
some new cable.  I would look for a good commercial battery shop that  
can
make up new cable with swaged connectors and replace the main cable
all the way to the positive post under the hood in one piece--hopefully
pulling the cable through with the old cable.  Otherwise it would mean
removing the front seat to access the cable run under the carpet.  The
problem with a butt connector repair is the shrink wrap insulation  
has to
be absolutely moisture-proof since the cable runs through the lowest  
part
of the interior and you won't be able to inspect it at regular  
intervals.  A lot
of work here, regardless of the repair method.

Replacing the cable with the OEM part is probably not a real option.   
The
PO of my sedan somehow had a bad cable end at the battery on his  
positive
cable.  The dealer socked him $325 for the new part # 4A1 971 225J  
(cable) ,
$105 for the battery, $69 diagnosis fee, $25 shop parts, and $310  
labor for
a new cable installation.  With environmental fee and state tax the  
total was
(gasp) $893.00.  The car was out of warranty by then, so this, and a  
couple
of other issues when it was in warranty prompted him to trade the  
car--to the
same dealer of all people.

Tom

> Date: Wed, 29 Oct 2008 16:13:17 -0600
> From: "Jerry Scott" <jerryscott at wispertel.net>
> Subject: Re: [s-cars] Burned battery cable
> To: "s-car list" <s-car-list at audifans.com>
> Message-ID: <681F5D52B7214254A4CD48188BB9F0FC at Jerry5976>
> Content-Type: text/plain; format=flowed; charset="iso-8859-1";
> 	reply-type=original
>
> Ron
> The battery was probably shorting out on the seat springs.  You  
> have to make
> sure that the  positive terminal does not touch the springs.
> Jerry
> ----- Original Message -----
> From: "ron kirkham" <rkaudifool at gmail.com>
> To: "s-car-list" <s-car-list at audifans.com>
> Sent: Wednesday, October 29, 2008 12:54 PM
> Subject: [s-cars] Burned battery cable
>
>
>> S-heads,
>>
>> I went out after work last night to fire up the 93 S4 for the trip  
>> home
>> and
>> had zero action upon turning the key.  I had no dash lights, no  
>> interior
>> lights, no stereo, nuttin.  The ignition switch is relatively new,  
>> so I
>> did
>> not suspect that.  Pulled the rear seat and see a pretty scary  
>> mess.  The
>> little plastic cover over the positive cable has MELTED.  The red  
>> cable
>> (the
>> medium sized of the three) is black from the terminal post back  
>> about a
>> foot.  The shielding on the black cable is brittle as far as I can  
>> feel on
>> it's length.  The very small guage wire is toast as well.  The  
>> terminal
>> post
>> on the battery had become hot enough to slightly melt the plastic  
>> case
>> itself and wiggle around in it's now enlarged hole.  I grabbed the  
>> wires
>> right at the terminal/post and moved them around a bit.  In so doing,
>> there
>> was a small audible (not visual) spark and the interior lights  
>> came on.
>> I was able to nervously start the car and head home after throwing  
>> the
>> seat
>> bottom in the trunk.  After turning the car off at the house, it  
>> re-starts
>> fine, but is parked util I can figure this out.  Started this morning
>> also.
>>
>> Questions.  I'm assuming the heat was due to corrosion within the  
>> wires
>> causing alot of resistance?  The terminal post area does not have any
>> corrosion at all, but is now covered in melted plastic, so it's  
>> tough to
>> tell for sure.  Could this heat be caused by a bad or old  
>> battery?  The
>> battery is 3.5 years old and is a NAPA Gold.  It has been a little
>> sluggish
>> in the mornings lately, so probably on it's way out.  What else  
>> could be
>> causing enough heat in this area to do this?
>>
>> I'm thinking I need a new battery and new positive battery cable.   
>> KATE
>> seems to indicate this is a three wire harness.  One wire to the  
>> starter,
>> one to a junction somewhere and the little wire not indicated  
>> where it
>> goes.  Anyone have experience on this replacement?
>>
>> Anybody got any other ideas as to what might be going on?  I did  
>> install a
>> McCullough HID kit about two years ago, but other than that, no  
>> electrical
>> work.
>>
>> As always, any help appreciated.
>>
>> Ron Kirkham
>> 93 S4 229K (crispy)