Is there a screw or sharp edge on the firewall that cut into that cell?
Check the battery for holes, tray for sharp edges/ protruberances
I don't post much, but I am always lingering, reading your emails. I am not really into the social emails, and usually when I have some advice or a suggestion, someone else is more knowledgeable or has responded before I get to the mail.
Luckily, my car is very reliable, and allot of things are documented out there. Usually I can find solutions to my problems with a quick, or sometimes more in depth google search.
This time I haven't had as good of luck.
About a year ago, the 300d wouldn't start, the battery was dead. I sent my wife to work in the Astro van, and put the car on a charger. Well the battery did not charge. I hardly use the SDL, and it had a battery that was only about a year old, so I took it and put it in the 300d.
Now that I had a known good battery, I tested to be sure the alt was charging, and it was. I also tested to see if anything was causing a drain with the car off, and nothing was. So, I just shrugged and decided that the 5 year old battery just decided to give up that morning, and left it at that.
Fast forward to a couple weeks ago (over a year from previous troubles). The battery is dead. Send wife to work in the astro van. Put on the charger. This time I look and see that one cell is low on water, and I top it off with distilled water. Battery charges fine. Checked alt output, OK, checked for ignition off drains, OK. So all is OK. weird, but I had always heard check batteries as they may required maint (water), I just haven't ever run across one needing any before.
I think all is well in the world, but a week later and I have the same problem. Battery dead (well wont start the car), I check and the same cell is low. I top it off and charge the battery and all is well again.
Repeat this procedure again and again, and it is just puking out of the one cell, and so here we are. I have tested the alt and it puts out about 14.1 so I don't think it is over charging. Odd or moaybe just coincidence but I still have the 6 year old battery, I went and looked at it, and it was empty in the same cell... This 'new' battery is over 2 years old, so out of the free replacement warranty.
Ideas comments welcomed.
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-Dean E. Chandler
'83 300D