Alternator Wire v. Header = FAIL
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2004-2007 Cadillac CTS-V General Discussion Discussion, Alternator Wire v. Header = FAIL in Cadillac CTS-V Series Forum - 2004 - 2007; After months of random electrical issues (under hard acceleration: service stability control, airbag, abs, nav screen cutting out, ect.) the ...
  1. #1
    whisler151's Avatar
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    Alternator Wire v. Header = FAIL

    After months of random electrical issues (under hard acceleration: service stability control, airbag, abs, nav screen cutting out, ect.) the V is finally fixed. The alternator wire was being burnt by the header and arced a nice hole in it. Turns out the alternator wire was plugging the hole in the header so i couldn't hear that I had a leak, until the dealership replaced the wire. Then is was CRAZY.

    After $798 to fix the wire at the dealership, I decided to drop the header myself and take it to a welder ($20). Dropping the header was not as hard as I though. Thanks to Lollygagger and Dannboss for the help (had a few questions) and CIWS for letting me borrow the Rhino Ramps.

    If you have headers, check your wires. Jack up the V and look at all the wires close to the header. Last thing you want is to be stranded with no power.

    I cannot tell you how horrible the car sounded with that hole in the header.

    Alternator wire and header


    Header


    Alternator wire

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  3. #2
    bneal1022's Avatar
    bneal1022 is offline Cadillac Owners Enthusiast
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    Re: Alternator Wire v. Header = FAIL

    so is the new factory wire routed the same? Did you wrap it? tie it back? I'm getting to headers soon and have some inswool fiber wrap and reflective heat wrap to go over it. It should prevent any radiant heat damage, maybe even some contact. got a pic of your new location or remedy?

  4. #3
    JD03Cobra's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Sorry to hear but I appreciate the info...My headers are getting installed on Tuesday. Was that the passenger side?

  5. #4
    shadybx7's Avatar
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    Re: Alternator Wire v. Header = FAIL

    wow.. sick hole.. sorry to hear about you dropping almost a G on something other then a gofast mod.. my condolences

  6. #5
    lilgCTS-V is offline Cadillac Owners Enthusiast
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    Re: Alternator Wire v. Header = FAIL

    dam im sorry to hear about that loss, i guess thats on my todo list.

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    Re: Alternator Wire v. Header = FAIL

    Quote Originally Posted by JD03Cobra View Post
    Sorry to hear but I appreciate the info...My headers are getting installed on Tuesday. Was that the passenger side?
    Looks like driver side to me... unless he flipped the pic that is.

  8. #7
    UnsafeAtAnySpd's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Looks familiar...

  9. #8
    whisler151's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Quote Originally Posted by JD03Cobra View Post
    Sorry to hear but I appreciate the info...My headers are getting installed on Tuesday. Was that the passenger side?
    Thanks. It sucks but sh*t happens. It was the driver side.

    Quote Originally Posted by greddy91 View Post
    Looks like driver side to me... unless he flipped the pic that is.
    Yep.

    Quote Originally Posted by UnsafeAtAnySpd View Post
    Looks familiar...
    Yeah I know, I read most of your threads regarding this issue. They were very helpful. Thanks.

  10. #9
    CIWS's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Possibly a hole that could be used to put whistle tips ?


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    Re: Alternator Wire v. Header = FAIL

    that sucks!

    I can't believe it cost $800 to replace an alternator cable!!

    How much was the cable? How long did it take to replace?

  12. #11
    whisler151's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Quote Originally Posted by perfect View Post
    that sucks!

    I can't believe it cost $800 to replace an alternator cable!!

    How much was the cable? How long did it take to replace?
    Cable was billed at $275 i believe. The rest was labor. The wire was resting in and partially melted to the header. I will say, they did a great job of re-routing my wires so this would not happen again. The new alternator wire is no where near the header now!

    I dropped it off on a Thursday, It took them a day to get the wire done. They also replaced my rear diff bushing (under warranty) so I didn't get my car back till Monday.

  13. #12
    Kmajecki's Avatar
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    Re: Alternator Wire v. Header = FAIL

    This happened to mine as well but i was lucky and caught it really early. I routed it differently and placed one of these spark plug boot heat protectors over the wire near the header just in case


  14. #13
    perfect's Avatar
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    Re: Alternator Wire v. Header = FAIL

    What could possibly be so special about this alternator cable that it costs $275!?!

    It's just a basic stranded copper (4awg??) cable with heavy insulation? Could have just bought 10 feet of 4awg from your local car audio store and soldered/crimped on the appropriate connectors...and then installed it from the positive of the battery to the positive of the alternator?

    Or am I missing something?!?!

  15. #14
    whisler151's Avatar
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    Re: Alternator Wire v. Header = FAIL

    Quote Originally Posted by perfect View Post
    What could possibly be so special about this alternator cable that it costs $275!?!

    It's just a basic stranded copper (4awg??) cable with heavy insulation? Could have just bought 10 feet of 4awg from your local car audio store and soldered/crimped on the appropriate connectors...and then installed it from the positive of the battery to the positive of the alternator?

    Or am I missing something?!?!
    Those were my thoughts, however, I do not have the time or patients to fab an alternator cable. I drop off my car at the dealer, get a 2010 CTS to drive, and pick up my car when its done. No inconvenience, just money spent. At the time I didn't know what the issue was. I had suspected the alternator wire, but wasn't sure. When it comes to electronics on the car, I'd rather let the dealer handle it.

    The header on the other hand was simple. I knew the exact problem (a hole) therefore I could address it. Didn't take long and no guess work.

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    Re: Alternator Wire v. Header = FAIL

    So this was the driver side header? In the other thread Heavymetals referenced the passenger side, does this wire wrap all the way around the block or something?

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