[scoobysteven]

I have a 1999 Astrovan with an electrical problem. Rather regularly, the vehicle lights will dim, gauges swing back and forth, voltage drops low, pretty much everything electrical stops working, and car dies. Let the car sit, runs normal with no hint of issues. I know my way around cars, I am no noob. I completely removed and inspect both battery cables, replaced the positive cable. Cleaned and inspected all connectors, even the ones at the starter. Some wires to starter were spliced and repaired in the past, not sure if they might be the problem, seems as if the wire gauge thinkness is not consistent, but would this cause my problem? Does this year and model van have any common issues consistent with my description of this problem. It is really becoming a common issue now. Any suggestions appreciated.

 

[astro355]

What type of connectors are used on the spliced wires?

And which wires have the inconsistent gauge thickness problem? Battery cables or smaller 14, 16, and 18 gauges wires?

 

[scoobysteven]

What type of connectors are used on the spliced wires?

And which wires have the inconsistent gauge thickness problem? Battery cables or smaller 14, 16, and 18 gauges wires?

There are 3 wires, other than the main battery cable, that all collect at the solenoid, all of these wires have been spliced and repaired. What is strange is that the largest of these wires, other than the battery cable, has been repaired with fusable link, and this vehicle is a newer Astrovan(1999) with removable blade type fuses and fusable links, in the fusebox near the battery. This fusable link is soldered in down by the starter. The gauge thickness on these three solenoid wires seem strange, but I'm just not positive they would be the root of my problems.

 

['cudapaul]

You should wait for the problem to occur and then try to make some voltage measurements, starting from the battery and then progressing farther into the electrical system. I don't think it is the battery, starter, or alternator themselves, but most likely a corroded or intermittent wiring connection or connector since it works some of the time.

Also, you should consider getting an FSM (factory service manual) for your van which will contain schematics of the electrical circuits in your van, besides everything else mechanical. Reviewing the manual will give you a better idea of where to look, and will definitely decrease the amount of wasted time trying to figure out the wiring (unless you are normally a VERY lucky person).

 

[scoobysteven]

Found the problem, it seems to be common as I've seen it on another car, same make/model/year as mine, since my remedying the issue. After checking the battery, alternator, replacing positive battery cable(with NON-OEM), cleaning connections on both ends, I checked the main power cable running from the positive battery terminal to the engine bay fusebox. Remember, I used non-OEM cable from Autozone, and simply merged the old cable to fusebox, with the new main, positive battery cable. Turns out, the OEM GM positive battery cable uses a defective cable/insulation design. The corrosion infiltrates the cable. From the outside, the cable looks fine. If you slice the cable(the one on the positive battery cable leading to the engine bay fusebox) lengthwise, white corrosive powder will be presently abundant. After driving, say at night with headlights running, the cable will heat up due to resistance, then lights dim and car dies. Let the car sit 15 minutes, car fires up and runs like normal, only to repeat. Though the remedy might seem simple and obvious, I wanted to offer my information for others who experience the same. I am not new under the hood and have many years of shadetree mechanical experience, but this one challenged me.

 

[meu325]

Good to know I'm getting weird electrical problems too. Do you know if the Batt positive to starter get defects too?? I took of and check and remount because looks fine, change pos to starter to alternator. Check but not change pos to fuse box.

Now I've got fuel pump electric sistem problems but when car was working was some weird stuff with lights and gauges going on, thanks.