Lost all electrical power.

[dachshund]

Good morning,

02 E350 7.3. On shoulder. Running down the interstate and everything went dark. Engine shut off and zero electrical power. I have no power at the distribution box under the hood. There is no power to the stud/wire from the batteries. Trailer battery charge 40 amp fuse blown. Tried jumping from battery + to Stud at distribution box and major sparks. ????????? I have DC clamp-on amp meter, volts and continuity meter with me. Thanks.

Update: I have continuity between distribution box + post and battery ground. Also 12.4 volts between battery positive and distribution box + post. Not good. I'm guessing I have that wire grounded to the chassis somewhere between the battery and the distribution box.

I'm going to take that wire off at the distribution box and jump the box to the battery and see if I get power or sparks.

Update: Isolated the + distribution box feed wire(took it off) and still major sparks when I jump from battery + to the Distribution box lug. Checked the distribution feed wire and it has battery voltage but returns back to zero when connected. So that tells me I have a short further up the line and when connected it must be opening a circuit breaker. Sound right?

 

[BIG JOE]

Starter.. shorted to Ground ?

Disconnect the starter battery lead.. then test for voltage/symptoms with the booster battery ?

Joe

 

[DaveBen]

You will have to check all the battery leads for corrosion and tightness. Make sure to check both ends of these cables. One cable feeds the starter and most of the other loads. Get under the truck and verify the connections to the starter. We all go through this process when we have this type of problem. Good luck!

Dave

 

[dachshund]

Got it towed home. Batteries are less than a month old. Terminals cleaned and No-Ox-Id used when installed. Just got it in the shop. Thank guys. Will report back.

 

[dachshund]

Report is good. All fixed.

Alternator shorted out inside. Had continuity from the + stud on alternator to case. Also The case was cracked but had been for some time as the crack was oxidized just like the rest of the case. Looked like one of the bolts was tightened to tight at the factory(Auto Zone, made in Mexico) as that is where it was cracked. No idea if this had anything to do with it shorting out. This in turn blew the fusible link in the wire that powers the distribution box. Wala, power out.

 

[JLDickmon]

I was gonna say,that sounded like a blitzed fuse link.. the sparkages at the alternator I did not expect, however..
Great job keeping us updated on the fix!