Friends:
I've reviewed threads extensively on how to install and solve issues with the installation of the CS-144 GM Alternator (A/C Delco version and Duralast version) in a 1984 FJ60, but I am at my witt's end. I've been trying to solve a recurring alternator charging problem for about 6 months -- at first the alternator works and charges. Then, one day, it stops. This has occurred on at least 4 replacement alternators. Clearly, there is a user error here. That would be me.
Why I installed this beefed-up alternator:
The existing Toyota alternator (55 amps) could not keep up with the upgraded electric on my truck -- Holley Sniper EFI (courtesy of Mosley Motors), a DUI distributor (courtesy Voodoo Cruisers when I purchased a wonderfully rebuilt 2F), dual Derale electric fans (at Summit), fog lamps, etc. The CS-144 seemed like the best solution because of part availability for the long term, 140 amps of power, and other IH8Mudders had successfully installed them.
Nature and symptoms of the problem:
After solving some alignment problems of the belt that goes around the alternator, a Saginaw power steering pump (no more incessant leaking from the Toyota model), and the harmonic balancer, I was certain I had good reliable belt traction. More importantly, I wanted to make sure there wasn't too much uneven pressure on alternator shaft. My AGM battery is never fully discharged and never starts lower than about 10 to 11 amps of charge. It is my understanding that installing an alternator on a fully discharge battery can damage the alternator. In most cases, the truck starts the alternator gauge reads right at about 12 amps (and the electronic Sniper monitor digitally reports about the same number of amps). Fairly quickly, the alternator will activate and I can see the charge gauge jump up to 13 to 14 amps, which indicates the alternator is charging the battery. The alternator runs very warm, but I assumed this was normal. Days or weeks will go by and then -- one day -- I will start the truck and the alternator does not charge and I watch the amp gauges slowly dwindle and confirm that charging is not occurring. I have no idea what is going on. Again, this has happened with at least 4 alternators (new and rebuilt).
How the alternator is installed and what I have attempted to trouble shoot:
Wiring. The Toyota plug has two wires, but the GM alternator plug has four wires. It is my understanding only two wires are used from the GM plug, which has PLFS wires. The S wire (the large red one) connects directly to the BAT stud on the back of the alternator. A new heavy 2 gauge wire then runs from the BAT stud (through a circuit breaker, 150 amps) to the positive pole on the battery. I upgraded this wire to the battery to accommodate the great amp alternator. The L wire goes to the Toyota charge indicator wire.
Charge lamp relay. I thought my problem might be a charge lamp relay. But, I replaced it with another. Same symptoms occur.
Charge lamp in instrument cluster. Possible problem here. I have made certain the incandescent bulb is good and also used dialectic grease to make sure there is a good connection. My charge light never lights up at start-up or at any time.
Fuses. All the fuses in the fuse box are good and properly sized.
Wiring harness. I recently installed a newer wiring harness from another FJ60. Mine had a short in it and fraying, so I wanted to make sure that it was solid and reliable.
WHAT AM I MISSNG? Thank you for your suggestions and comments, Roger
I've reviewed threads extensively on how to install and solve issues with the installation of the CS-144 GM Alternator (A/C Delco version and Duralast version) in a 1984 FJ60, but I am at my witt's end. I've been trying to solve a recurring alternator charging problem for about 6 months -- at first the alternator works and charges. Then, one day, it stops. This has occurred on at least 4 replacement alternators. Clearly, there is a user error here. That would be me.
Why I installed this beefed-up alternator:
The existing Toyota alternator (55 amps) could not keep up with the upgraded electric on my truck -- Holley Sniper EFI (courtesy of Mosley Motors), a DUI distributor (courtesy Voodoo Cruisers when I purchased a wonderfully rebuilt 2F), dual Derale electric fans (at Summit), fog lamps, etc. The CS-144 seemed like the best solution because of part availability for the long term, 140 amps of power, and other IH8Mudders had successfully installed them.
Nature and symptoms of the problem:
After solving some alignment problems of the belt that goes around the alternator, a Saginaw power steering pump (no more incessant leaking from the Toyota model), and the harmonic balancer, I was certain I had good reliable belt traction. More importantly, I wanted to make sure there wasn't too much uneven pressure on alternator shaft. My AGM battery is never fully discharged and never starts lower than about 10 to 11 amps of charge. It is my understanding that installing an alternator on a fully discharge battery can damage the alternator. In most cases, the truck starts the alternator gauge reads right at about 12 amps (and the electronic Sniper monitor digitally reports about the same number of amps). Fairly quickly, the alternator will activate and I can see the charge gauge jump up to 13 to 14 amps, which indicates the alternator is charging the battery. The alternator runs very warm, but I assumed this was normal. Days or weeks will go by and then -- one day -- I will start the truck and the alternator does not charge and I watch the amp gauges slowly dwindle and confirm that charging is not occurring. I have no idea what is going on. Again, this has happened with at least 4 alternators (new and rebuilt).
How the alternator is installed and what I have attempted to trouble shoot:
Wiring. The Toyota plug has two wires, but the GM alternator plug has four wires. It is my understanding only two wires are used from the GM plug, which has PLFS wires. The S wire (the large red one) connects directly to the BAT stud on the back of the alternator. A new heavy 2 gauge wire then runs from the BAT stud (through a circuit breaker, 150 amps) to the positive pole on the battery. I upgraded this wire to the battery to accommodate the great amp alternator. The L wire goes to the Toyota charge indicator wire.
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Charge lamp relay. I thought my problem might be a charge lamp relay. But, I replaced it with another. Same symptoms occur.
Charge lamp in instrument cluster. Possible problem here. I have made certain the incandescent bulb is good and also used dialectic grease to make sure there is a good connection. My charge light never lights up at start-up or at any time.
Fuses. All the fuses in the fuse box are good and properly sized.
Wiring harness. I recently installed a newer wiring harness from another FJ60. Mine had a short in it and fraying, so I wanted to make sure that it was solid and reliable.
WHAT AM I MISSNG? Thank you for your suggestions and comments, Roger