Lesson learned: Don't mess with a dying alternator
 

My wife's car had a flat tire so I let her take my truck this morning. I didn't have time to go get a patch because I had to meet a client down state so I took the old car.

I've suspected my alternator has been dying for a while (random dash lights would flicker, the voltage warning would occasionally splash light and then quickly go out) but the car kept starting so I disregarded it despite being at the mileage these cars traditionally lose the alternator.

So I'm halfway up from the beach and start smelling a horrid smell, almost sulfur like smell but it's faint enough that I thought it was just something from the surrounding farmland.

Well, I park the car and notice fluid (condensation) dripping from the front which I thought was odd considering my A/C hasn't worked for three years. I then pop the hood to a puff of steam and a heavy sulfuric smell. I look down and see the battery (likely overcharged) shooting off steam out of both ends.

I'm shaking realizing I drove about 50 miles with a battery one small spark away from the battery exploding right next to the gas tank.

be sure to neutralize the acid that the battery's likely spewed into your "frunk" and underlying crossmember, etc.

Yes, will do. Doesn't look like it spewed any acid fortunately.

You said that it was spewing steam... that steam is acid steam. :eek:

****, I guess that would make sense. I called the shop and asked them to neutralize it as soon as it gets there.

They were able to clean it up when it got there. Small victory, I suppose.

The carpet will melt from the fumes also. Get it out and wash and backing soda it in the area by the battery.

I just went through an alternator fiasco.

My recommendations:
1) If your car has over 100K miles, it's coming, keep it on your mind
2) If you rebuild a gauge, get them to add a voltmeter
3) If you don't have a voltmeter stick a INNOVA 3721 Battery and Charging System Monitor in the cigar lighter every once in a while
4) Don't ignore weird electrical signals

In my case I had a spike and both main beams went out, high beams ok. After replacing the turn signal switch and still having a problem I replaced the bulbs, until it happened again and then the high beams went too (at night). Voltmeter showed spikes all over the place to 18. Voltage regulator dead. I decided to replace the whole thing.

Gets better. After hearing rebuilt alternators occasionally crap out I decided to get a brand new one. Got a deal through a dealership (on a side note the dealer new OE part is identical to the pelican new OEM Valeo). When I changed it out the Magnesium shroud had a small crack....put it back and worry?, find a mag welder?, find a used one?, buy an aftermarket aluminum one? (what I did).

Don't forget to put the little vent tube back on the battery when you replace it. Good times.

Thank you all for your recommendations.

There was no damage to the front pan. Wiped it all down with baking soda in the entire front tray and underneath, then used Folex on the carpeting and let it air out, then used Optimum No Rinse throughout the front trunk.

http://i.imgur.com/10VV8lB.jpg

Also the car is no longer hesitating below 3000 rpms like it had since I bought it. It feels like a new car altogether with a new alternator.

Bonus pic of the GT3 in the showroom.

http://i.imgur.com/HxdEcA9.jpg

Nice and Clean :D Congrats and no go enjoy her, you neglected her long enough :D

Glad you got it fixed with no lasting damage.

If you are willing to go with an aftermarket solution to installing a voltmeter, you can get a gauge from your local Autoparts store and install it yourself. Here is what I did:

http://forums.pelicanparts.com/uploa...1430685941.jpg

How long do these last?

I've got 120k on the clock, but have a service record for an alternator replacement in 2000 (no mileage stated, but it was probably around 45k).

Just curious if anyone knows what to expect.

My battery charge light stays on for about 5 seconds after starting. I do have a receipt for alternator replacement a few years back.

I'm wondering if the alternator is on the way out. I also tried jump starting another car from it, but it just couldn't generate enough current to work.

The charging system on these cars are problematic at best. With the number of people who have pulled their AC compressors, I'm surprised nobody has rigged the bracket up for a modern, carefree, powerful, standard, cheap, aftermarket alternator.