Please help I have a 91 rs 305 tbi. The alternator wire that goes to the junction box on the side of the battery for the wires for aux ,+ battery terminal and starter wire... was blown. I replaced it with a 10 amp fuse and blows immediately I hard wired to see if it would get hot and it gets extremely hot as it will melt. Alternator is brand new and so is battery both tested good. Alternator was reading 13.6 volts. Can't charge battery or have car run of alternator because the wire keeps getting hot and burning and/or blowing fuses. What would cause only the Alternator wire to the terminal no other wires to get hot and burn up.

 

I this case, I'm not sure, but normally if it's just that wire you may be looking at excessive resistance caused by corrosion or a bad connection somewhere. You may want to have a good look at that wire from end to end. It may also be shorted to ground (dead short). GL

 

so I checked both ends and rerouted a singular bypass and they all get hot or pop a fuse im stumped at this point

 

Is this the alternator output wire?

What gauge wire was the original?

What is your alternator's rated output amperage? Kinda guessing it's enormously more than ten amps.

Using what gauge wire?