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Hey Guys, take a look at your plastic connector to the R/R. I found a bit of overheated wire on one of the three phase wires coming from the PMA. You can see that it discolored the connector area where the spade associated with the bare wire is located and seated. That bare wire is the one that overheated and made it easy to crack and break off the insulation. It also got hot enough to partial melt some of the other phase wires. Crimps are all good, output wires good, so I'm scratching my head a bit on why this would overheat. One of the A&P/IA mechanics I work with thinks it is most likely due to the fact that I had applied some dielectric grease to the terminal connections during install. Evidently, a big "NO-NO" and certainly not recommended. I am currently (bit of a pun there) still investigating that on the Matronics Aero-Electric forum with the electrical gurus. So, be heads up, pull those cowls and take a look at things pretty close every couple hours.
Wow David, could this mean there was very high resistance at the connectors? I wonder if that is why my prewired connector was so tight I couldn't remove it.
Certainly looks like things got HOT there. Good catch on the inspection.