02 QX4 alternator change and battery sizzle

[laider]

My first post. I have a 02 QX4 with about 130,000 and it's been totally trouble free, stock no mods including the sound system. Friday night my wife and I were eating out and after we came out wouldnt start. Did have a clicking. Got a jump start and made it home about 5 miles but as I was pulling in my street dash lights started going crazy. Yesterday made it to Autozone and they tested the battery and it was bad but also said alternator was not doing its job either. I bought a new battery and had autozone check the alternator again thinking maybe it would be better. NOT! They didnt have an alternator in stock but said it would be here today. I ordered it and went home to begin the task of taking off my old one. It was a pain. Got the new one today and put it on, pain also. I finally was buttoning everything up with a little smille in my mind and hooked up the postive battery cable then the negative. When I first touched the negative cable to the post it sizzled a little. I thought maybe it was the battery grease I had put on and went ahead putting it on. It sizzled more and acted like it was heating up and then a crack or pop under the hood. It sounded like it came from drivers side near the fire wall ( fuse box area). I took cable off and put the multimeter on the posts and battery still read good. Started it and with full load alternator read out a little above 14 volts. Put the cable back on and no sizzle. I assumed I had blown a fuse somewhere and probably have a short. I checked all the small fuses inside and out but all look good. Car starts and drives fine and I can't find anything that does not work. All accessories I've tried work fine, fan comes on. Llights are good all the way around etc. Any ideas.

Thanks.

Jeff

[laider]

Looked at my post and sorry it was so long. Does anyone have a comment or idea regarding the sizzle and pop

[Pathfound49]

A little sizzle is fine when connecting a negative battery terminal.

[zach7685]

If it runs I wouldn't worry about it. If the Charging system light (batt) light comes on I say take a look at it.

[Towncivilian]

My first thought would be a fusible link, but I'd think you'd have starting issues if one were damaged.

[laider]

Thanks for the responses. I have now driven it about 75 miles with no noticeable issues. The fusable link or a relay was my first thoughts also but I haven't identified anything. It was more than a typical little sizzle and the heat it generated actually marred the negative post...and the pop was seemingly significant . If it did blow something I now do not see that resistance and feel if I did find a burnt fuse and replace it that the same thing would happen. Just a feeling. Since the fuse is burnt , in theory, the short or resistance isn't showing. Anyway to further test this?
Thanks again and happy to be part of this forum.

Jeff--in Colorado