Again, with an ipod directly connected as source, amp plays fine. Only when tied into the same 12v as the source does the amp pop fuses. Im not trying to say you didn't bench it, just that the problem may not have shown up on the bench.

The transformer on the 25 board?

That's correct. Amp with green power indication, no rca`s connected. I measure ~11.6v DC between ALL 12 speaker terminals and GND.

Yeah strange indeed. Especially that when using an external source.ipod(not connected to car gnd) everything works fine. Only pops fuses when using Alpine(obviously same pwr,gnd) AND only "25" side of 66.
Any idea the gear used when it was benched?

Eric, I measured what you asked. Between "25" and "44" speaker terminals I get around .2 volts which Im guessing is OK. However from ANY speaker terminal on either amp to GND I am getting 12volts!!! I am guessing thats NOT good.... The other thing is when you say middle terminals...

Eric, im going to check this when I get home. Just a quick question though. Wouldn't a rca shorting to ground cause a current draw on both amps? Only the 25 side pops....44 side works perfect.

I've tried that. Its not cabling or speaker related.

Caps have been done, by eric im told. All outputs of processor
work on "44" side, pop fuses on "25" side.

I have a route 66 with a weird problem occurring. Im using the 66 with an Alpine PXE-H660 processor. When the 2 are connected, and the Alpine turns on, the fuse in the "25" side of the 66 immediately pops. The "44" side works just fine. As an experiment I connected my ipod direct...