[mylogylo]

So this morning I had to replace my battery for the second time in a year. They both ruptured and leaked all over the driveway. Why would this happen? I did find that the positive cable appears to have seen some serious heat. It is brown and cracked now instead of red. What gives? Any thoughts?

The only electrical accessories I have is an electric fan, and some cheasy fog lights.....so far ;-)

[saharadream]

check all your wiring that would go to the battery and make sure nothing is grounding out or any chaffed wires. if your positive cable grounds itself out someplace like on the frame or motor it would make it heat up therefore causing your battery acid to boil and crack/explode

[zeus87gn]

Have your alternator professionally tested.
Most likely, the internal regulator is dying and allowing an overvoltage condition.

[EABiker]

Originally Posted by zeus87gn

Have your alternator professionally tested.
Most likely, the internal regulator is dying and allowing an overvoltage condition.

Yep! This would be my first step.

[mylogylo]

I had the guys at Checker test the charging system. They just hooked the tester up to the battery while it was running. Is there a better test I should have done?

[zeus87gn]

The alternator has to be spinning to test it.
What did they tell you?

Is there an electrical auto shop in your area?
They have better knowledge to diagnose this.

[mylogylo]

They said the alternator/charging system tests out fine. His guess was that at somepoint the cable got fried and now it is just toasting the battery everytime.

I can figure out and fix most things, but troubleshooting the electrical side is certainly not my specialty Time to buy some brews.

[rustywrangler]

What I would do is replace all of your batt cables and ground cables to start with.

[EABiker]

The voltage regulator may be intermittent, and it was OK at the time they tested it. Keep and eye on your voltmeter when you drive, and watch for a higher than usual voltage. Overvoltage in will cause a battery to swell more often than overcurrent out.

[laybackman]

High resistance in corroded wires may very well be the culprit. But usually other troubles happen also like trouble starting after you hit a bump or move the battery cables around. Make sure you have the right alternator in stalled also.
Blowing up two batteries in one year is cause for concern....plus it can get messy and expensive. The alternator charging circuit is not controlled internally but through your PCM's field generator circuit located at pin #20. Check that wire for exposed copper.

If that circuit was bad inside the PCM I would suspect that your CEL would snap on. There are several trouble codes to look for, in that case, #41 and especially #46.

[87TPIYJ]

if your wire is burnt, then your amperage is to high. something is drawing to much current for that wire to handle. check the positive junction box and all the wires coming from it. in all likely hood you are grounding some where. and with that wire being the way it is you are very likely to start an electrical fire! no bueno.

[zeus87gn]

This may all be tied together.
The corroded cables are causing a voltage drop across the battery, thus creating higher currents than the batt or cables are designed to carry. Especially during starting. The alternator is trying to put out more power across those cables and just adding to it.

Yes, definetely replace the cables if they are corroded and/or burnt.
Have your alternator checked out by an electrical specialist.
I'm guessing Checkers is a parts store. They aren't specialists.
Find an elecrical repair shop and they can help more.