Battery Wiring Harness - Root Cause

Just a follow up on this issue...APPARENT ROOT CAUSE.

While trouble shooting what appeared to be a failed starter I've learned that the large positive red wire running from the battery to the starter was actually...welded to the exhaust manifold!

Apparently the harness got too hot, melted the protective bundle wrap and the wire insulation allowing starter current to weld the wire to the manifold. That's what it looked like anyway.

I had to pry what was left of the wire off the manifold with a large screw driver. Unbelievable for me, I've never seen anything like it. I've rebuilt the harness using a new piece of battery cable and will install it tomorrow am.

Thank you all very very much for your help.

bob



Burned Wire



Repaired Harness