smoking alternator connection

[yaris2010RS]

Originally Posted by dogsridewith

What would OP's smoking alternator terminal-to-cable-connector connection do to the working parts of the alternator?
--Locally heat up the terminal post and what is touching it.
--Make alternator work full power all the time to maintain desired output voltage to system. (OP's voltage drop measurements suggest this.)

I don't see that either of these effects would have necessarily hurt the alternator...do think I'll double-check that connection.

so as my update post suggests, I did end up "fixing" it. I wish I had taken better photos but the concern wasn't the main connection on the alternator, but instead the connection inside the alternator to that post. the entire post form the base was getting almost red hot.

I removed the alternator and disassembled the back cap of it (where the regulator and brushes are housed) and found some corrosion. took it all apart, cleaned it up and now getting a healthy voltage.

I have found a junkyard alternator that I have on my bench for the next time it acts up. the heat could have possibly damaged the regulator but in this case it seems fine.