Friends, I have a '93 Legacy wagon with 230k. In early February I swapped my failing alternator with the '96 reman (see http://www.ultimates...3-legacy-wagon/ for details).
Yesterday, I was driving home from work, and I could tell something was very goofy with the electrical system (started funny, delay/loss of power in acceleration, blinkers sounded weird). When I got home and shut off the engine, it would not restart - won't even turn over at all. This is the exact behavior I had recently when a squirrel chewed through my alternator wire - which I repaired. My assumption, therefore, was that my splice had come loose somehow, or some other wiring issue.
The two-wire connector is just fine...reading a little under 12V to the battery and also impedance is 0 to the battery. So that's not it.
However, the big two-wire socket connector on the top - weird stuff there. I just put this in a few months ago, and the nut and bolt are super corroded. I removed the nut and found that it had partially fused with the bolt - both are screwed up and I cannot get the nut to tighten down anymore. Appears the bolt may have to be replaced...if that's even possible...I'm going to get a free AAA tow to my mechanic on Monday morning.
The big question is: what would cause rapid corrosion and metal fusing on that connector?? Could it be related somehow to using a different alt than spec? A sign of a different electrical problem?
Also, could this possibly have anything to do with my latest squirrel problem? (see http://www.ultimates...erature-sensor/) (I have since added split tubing to EVERY exposed wire under the hood. Sigh.)