Problem for the spark chasers
 

First off let me say thanks for all the little pieces of info you all have provided in the last couple of weeks since I discovered this board.
Here's the problem; Every time my cooling fan comes on I get a spark at the positive post on the battery. I have cleaned the post, replaced the ground strap, and verified that the charging system is in good order. The battery, Alt, and reg all check good. The spark at the battery will eventually melt the 3 leads coming of the post as it has in the past and result in the car not starting. Anyone ever encounter this before? I believe it may not be strictly related to the cooling fan switch or relay due to the fact that other increased electrical loads generate heat at the battery post as well. I have an early 85 NA. Thanks in advance.

Wow, sounds like you have a high resistance bridge somewhere, and the current draw is making things spark. I know you tried to clean everything, but have you tried to renew the three post wire connections by cutting the old end, stripping a bit of the insulation off, and re-crimping the connectors on? that might get your connections re-established.

E

High resistance was my immediate thought and after realizing I had the problem I cut and recrimped the leads at the point where good wire was available. This is the 3rd time I have done so and I also replaced the battery to be sure it was not that component. Resistance is definately a problem, but from where I do not know. I don't have a good schematic of the system so if someone would please inform me as to what is hard wired directly to the battery I'll start from there and work my way back to the faulty component. From the positive post I have the main battery lead and 3 12 gauge wires the I believe go to the ignition, alt, and the starter, is this correct?

I believe you are right, you can check in the Haynes Manual, or maybe somewhere in the Pelican Parts website ...

Do you 'see' the spark? or you just see the result of it eating away at your wires?

If it is not a bad contact at the battery, then it has to be that one of those wires at the positive pole is somehow grounded, providing a lower resistance path for the spark to occur, instead of the current going through the wires themselves ...

keep us posted,
e