Repair done in Part 2:
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2005 Dodge Grand Caravan 3.3L towed in. I opened the hood and found the negative terminal off. When I installed the terminal it arced like a welder! The customer doesn't do any work on their vehicle so not many things that can cause that kind of current discharge. Most likely being a faulty diode pack in the alternator causing a dead short. Alternator is right there so opted for the low tech approach.
I removed the main battery cable from the alternator then reinstalled the negative terminal. This time no major arcing! No further testing required! Needs a new alternator. End of story!
Except it was the end of the day and I felt like doing more! This alternator was incredibly noisy. Even with the main power cable off. After just a short amount of time running it got over 300*F. Right after shutting it off I checked resistance from the main power post to the case of the alternator. I got 0.8ohm. My leads are 0.2ohm so that's like half an ohm of resistance! I started filming a minute after that and it was up to 1.8ohms but that's still VERY BAD. This would be going through the diodes so it should be millions of ohms. This is what the new one tested as.
Thankfully on these Caravans the alternator is very easy to change!
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