Electrical Warning '07+ - Sprinter-Forum

kmessinger · 02-14-2009, 03:38 PM

Yesterday I happened to notice a potentially serious wiring defect on 2007 (and possibly up) Dodge Sprinters. The main power cable that runs from the alternator to the starter which contains a 300 amp fuseable link wears through the heat shrink on the fuseable link and grounds out on the metal bracket it mounts to as it crosses under the oil pan just above the power steering rack. In our case the vehicle had been parked for a few hours and the battery was dead, when boosted the "check alt battery" was on the display. I checked it out and it was not charging, while inspecting the wiring it was hard not to notice the large burnt section of main cable and scorch marks on the oil pan and melted plastic.http://www.rv.net/forum/index.cfm/fu...d/22420064.cfm

This info from another forum. I am going to check this as soon as the rain stops. Anyone here have any additional information?

Regards,

Keith

shanemac · 02-14-2009, 06:12 PM

I will be checking mine out to see for myself and post some photos either way.

shanemac · 02-14-2009, 07:11 PM

My cables look fine besides things being filthy then again I'm not positive what to look for ... hear are some photos

kmessinger · 02-14-2009, 07:35 PM

Thanks for that quick work! I still think I will check mine - I want to find the "metal bracket". Do you think you found that?

shanemac · 02-14-2009, 08:41 PM

I'm betting this one, the tie wrap holds harness tight against bracket could be chafing through on the back side i didn't cut or remove tie wrap but may have too in order to inspect shrink wrap properly...it may be better if the tie wrap wasn't there or a tie wrap not as tight... to help the harness breath a bit but don't want harness dangling poorly either.

shanemac · 11-13-2010, 01:49 AM

After watching this thread http://sprinter-source.com/forum/sho...=cable+battery and this post http://sprinter-source.com/forum/sho...34&postcount=5 and my second battery that died twice in the last few weeks i suspect a less than ideal cable health.

From what i read my eyes are still a bit cross eyed but new positive cable number is 68047520-AA correct? Is this positive cable standard for all 07 08 09's?

PLUMMER · 05-22-2011, 07:37 PM

Having same issue here. I just picked up my vehicle from the sterling dodge dealer and was on a trip north to pic up some material. Alternator and battery indicator and take to dealer was on the dash. Well with precious cargo and 148 miles from home and 120 from the nearest sprinter dealer I made some phone calls and electrical diagnosis. It was determined that I was maintaining 12.46 volts and the truck would continue to run. So I made it home and found the fuseable link melted just as pictured in the photo here. My ESP and ABS systems shut down but the truck could be turned off and restarted. The alternator and diodes checked ok, clutch on the alternator was still good but I was not getting anything over 12.5 volts at any rpm. My sprinter mechanic noted there is a splice on the 07's that is common to go bad , or it could be a volt reg problem. We will find out monday morning for sure. One thing I did notice was my red jumper post on the airbox had been used. It was at the dealer for 3 weeks getting body work done. Never had a battery issue before or needed jumping. Can you just replace the fuseable link or is there an underlying cause. If you bypass the link temporarily will it get you by till the part comes in? I too have a #3 glow plug bad and GP module, however that code comes and goes, and currently is not coming up? Does anyone know if you can repair the module with a hand built fuseblock like has been posted here for the 06 and older models. Thanks

02-14-2009, 03:38 PM	#1
kmessinger Join Date: Dec 2007 Location: East of San Francisco, deep inside a secret bunker, drinking martinis, playing rock and country. Posts: 995 Thanks: 85 Thanked 142 Times in 94 Posts	Electrical Warning '07+ Yesterday I happened to notice a potentially serious wiring defect on 2007 (and possibly up) Dodge Sprinters. The main power cable that runs from the alternator to the starter which contains a 300 amp fuseable link wears through the heat shrink on the fuseable link and grounds out on the metal bracket it mounts to as it crosses under the oil pan just above the power steering rack. In our case the vehicle had been parked for a few hours and the battery was dead, when boosted the "check alt battery" was on the display. I checked it out and it was not charging, while inspecting the wiring it was hard not to notice the large burnt section of main cable and scorch marks on the oil pan and melted plastic.http://www.rv.net/forum/index.cfm/fu...d/22420064.cfm This info from another forum. I am going to check this as soon as the rain stops. Anyone here have any additional information? Regards, Keith

02-14-2009, 06:12 PM	#2
shanemac Join Date: Mar 2007 Location: Alberta canada Posts: 1,000 Thanks: 310 Thanked 213 Times in 137 Posts	Re: Electrical Warning '07+ I will be checking mine out to see for myself and post some photos either way.

02-14-2009, 07:35 PM	#4
kmessinger Join Date: Dec 2007 Location: East of San Francisco, deep inside a secret bunker, drinking martinis, playing rock and country. Posts: 995 Thanks: 85 Thanked 142 Times in 94 Posts	Re: Electrical Warning '07+ Thanks for that quick work! I still think I will check mine - I want to find the "metal bracket". Do you think you found that?

02-14-2009, 08:41 PM	#5
shanemac Join Date: Mar 2007 Location: Alberta canada Posts: 1,000 Thanks: 310 Thanked 213 Times in 137 Posts	Re: Electrical Warning '07+ I'm betting this one, the tie wrap holds harness tight against bracket could be chafing through on the back side i didn't cut or remove tie wrap but may have too in order to inspect shrink wrap properly...it may be better if the tie wrap wasn't there or a tie wrap not as tight... to help the harness breath a bit but don't want harness dangling poorly either.

11-13-2010, 01:49 AM	#6
shanemac Join Date: Mar 2007 Location: Alberta canada Posts: 1,000 Thanks: 310 Thanked 213 Times in 137 Posts	Re: Electrical Warning '07+ After watching this thread http://sprinter-source.com/forum/sho...=cable+battery and this post http://sprinter-source.com/forum/sho...34&postcount=5 and my second battery that died twice in the last few weeks i suspect a less than ideal cable health. From what i read my eyes are still a bit cross eyed but new positive cable number is 68047520-AA correct? Is this positive cable standard for all 07 08 09's? __________________ 2007 Dodge sprinter 2500 NCV3, 144, high, no side or rear glass,suspension seats comfort version with arm rest,heavy duty front and rear sway bars,4.10 gears,parktronic system, booster heater,axillary heater,cruise control.

02-14-2009, 07:11 PM	#3
shanemac Join Date: Mar 2007 Location: Alberta canada Posts: 1,000 Thanks: 310 Thanked 213 Times in 137 Posts	Re: Electrical Warning '07+ My cables look fine besides things being filthy then again I'm not positive what to look for ... hear are some photos Last edited by shanemac; 02-14-2009 at 07:21 PM.

05-22-2011, 07:37 PM	#7
PLUMMER Join Date: Jun 2007 Location: MICHIGAN Posts: 382 Thanks: 89 Thanked 107 Times in 53 Posts	Re: Electrical Warning '07+ Having same issue here. I just picked up my vehicle from the sterling dodge dealer and was on a trip north to pic up some material. Alternator and battery indicator and take to dealer was on the dash. Well with precious cargo and 148 miles from home and 120 from the nearest sprinter dealer I made some phone calls and electrical diagnosis. It was determined that I was maintaining 12.46 volts and the truck would continue to run. So I made it home and found the fuseable link melted just as pictured in the photo here. My ESP and ABS systems shut down but the truck could be turned off and restarted. The alternator and diodes checked ok, clutch on the alternator was still good but I was not getting anything over 12.5 volts at any rpm. My sprinter mechanic noted there is a splice on the 07's that is common to go bad , or it could be a volt reg problem. We will find out monday morning for sure. One thing I did notice was my red jumper post on the airbox had been used. It was at the dealer for 3 weeks getting body work done. Never had a battery issue before or needed jumping. Can you just replace the fuseable link or is there an underlying cause. If you bypass the link temporarily will it get you by till the part comes in? I too have a #3 glow plug bad and GP module, however that code comes and goes, and currently is not coming up? Does anyone know if you can repair the module with a hand built fuseblock like has been posted here for the 06 and older models. Thanks

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