Charging System Problems

**RETMSG** · March 10th, 2016, 08:26 PM

I recently changed from long tube headers to short engine swap headers that would allow the exhaust to hang a little lower and clear the frame rails. Since the change, I now have starting issues. Prior to the swap the engine would fire and after a little coaxing would idle on its own. Now it acts as if the battery is bad. I had it checked and was told that the battery is fine. I took the starter in and was told it was okay as well. Today, while trying to track down the problem, I notice smoke rising from the throttle linkage while I was trying to start the car. The linkage was hot enough that I got a nice little blister on one of my fingers when I checked to see what was getting hot. Has anyone run into this kind of thing before? I have checked for wires that could be in contact with the linkage, but have found nothing. Any advice would be appreciated.

**Jeff W** · March 10th, 2016, 09:35 PM

I think this is an easy one. Check the large braided engine to chassis ground strap. On my little six is is on one of my starter bolts to the firewall. Sounds like it is trying using your throttle linkage for a poor ground. Maybe you took one end off during your header work.

A quick test would be to use a battery jumper cable for a temporary ground between some thing like a manifold bolt and your negative battery post.

I like your car, and the picture is great. How did you get the reflection on the floor and the white background?

**RETMSG** · March 11th, 2016, 07:57 AM

Thanks. The photo was taken at the Volo Auto museum in Volo, IL. Indoors of course with high gloss floors. They do a great job photographing vehicle they offer for sale and in their displays. This morning when my Son stopped by, he noticed spark arcing from the throttle linkage to the manifold. Definitely have a short somewhere near the firewall. There is very little that is stock about this Falcon. The overall body and the majority of the interior are stock but nothing else. It now sports a very healthy 408 Stroker backed by a MDL 5 Speed and 9 inch rear with 3.50 gears.

**Jeff W** · March 11th, 2016, 01:07 PM

Originally Posted by RETMSG

he noticed spark arcing from the throttle linkage to the manifold.

I really think that "spark" is the return electricity from your srater motor trying to find it's way back to ground.

Try the jumper cable test to be sure the engine is grounded. If that isn't it I will eat my hat (and it's a very nice hat).

Also - when I said "easy" I didn't meant easy to diagnose - I meant easy to fix.

I can thank BPVan for helping me discover the ground strap issue. I was helping him on his Mercedes wagon a few months ago and we thought it was a bad starter. Smoke was literally rolling off of the braided stainless exhaust coupler and it burned his arm. We had forgotten to reattach the engine ground strap when replacing the transmission.

**RETMSG** · March 13th, 2016, 05:48 PM

You were right. The 302 I took out of the Falcon did not have a ground strap of any kind. So I tried to run the 408 without one. Not a good idea. I borrowed the negative cable off my lawn mower and ran it from the block to the firewall and all is well. I'll have to see if I can find an actual ground strap tomorrow. The car still acts like it needs more battery when trying to restart it after it has come to operating temperature. Thanks for your expertise, I really appreciate it.