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Matt, Mechanical Engineer
Category: Car
Satisfied Customers: 22903
Experience:  BEng hons Mech engineering, in auto industry 22 years
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i have a 2002 Ford Mondeo 2.0 tddi, i went to start it

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i have a 2002 Ford Mondeo 2.0 tddi, i went to start it recently and discovered the negative cable from the battery to the gearbox has melted its insulation off, any ideas what could have caused this and is it an easy fix?

for the cable to run that hot it must have had a dirty connection or become high resistance due to corrosion over time

this is enough for it to run hot

I'd replace the entire cable with new and clean up the mounting points with a wire brush and use new fasteners at each end

hopefully that should do the trick
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