Alternator / electrical problem FJ62

[Ozone]

The issue started 2 weeks when I was driving home from a weekend in the mountains. All of a sudden the battery indicator, brake and AT temp light came on. When I got home I researched the issue and found several threads here that helped me trouble shoot. I removed the alternator and had it tested - it was bad. I also found a couple of ground wires that needed attention, so I fabricated new ones and replaced the old worn ones.

Since we where installing a new alternator, we decided to remove the AC belt as I will not be using the ac here in CO this fall and winter.
Fired her up and everything appeared to be in order. I did test the new alternator at the parts store before installing it. All I could come up with was a reman unit.

Yesterday I took her into town and was out running errands for about an hour. On the way back up the hill I started to get a pinging / sputtering noise. By the time I got to my driveway it all she would do to make it to the garage where it stalled.

Early this morning I double checked all of our work to make sure we hadn't forgotten to connect something. I started her and she fired right up, sounded normal. I let it idle for about 10 minutes and shut it down. This afternoon I went to take her for a drive and she started fine but when I put it in reverse I got the sputtering and it stalled. It would not start back up.

What am I missing??? I'm certain it is something simple. The AC belt only operates the ac condenser - right?
While it was running the volt meter indicated 12 - 14 so I assume the new alt is working?
Any insight will be much appreciated as I need to get the beast running. Archery elk season is open and I need to get into the mountains!!!

 

[lovetoski]

when you get the pinging/sputtering...are the dash lights (battery, brake, at) normal?

 

[Ozone]

Yes, all indicator lights are off and dash meters are normal.

 

[lovetoski]

Ok. That supports the hypothesis that the alternator is fine. As does the volt reading you have.

What's next? It's possible that in the process of replacing the alternator you screwed up something else. I've done this more times than I can remember. Triple and quadruple check everything you touched.

It's also possible that you had two things going on at once. This isn't unusual for an older vehicle. You've got one problem solved. Now you need to figure out the second problem.

Have you done the basic tune-up stuff - spark plugs, wires, dizzy cap and rotor, timing, air filter? Any of these (except air filter) could cause poor running like you are experiencing.

 

[Finally Mine]

Fuel filter or fuel pump? A dirty fuel filter put a bad ending to last years drive home from a great vacation. Spent a couple bucks on a fuel filter from NAPA and it took care of the sputtering and stalling.

 

[macko]

Vacuum in the fuel tank? When it stalls, remove the fuel cap and try again.

 

[Ozone]

We have done all of basic tune up stuff this past winter/ spring. The list of replacement parts and procedures is so long I had to go back and double check. The only thing mentioned in the above responses that we have not replaced is the fuel filter. I will replace that today.
I would think if it was the fuel filter that it would sputter even when in Park or Neutral. It only wants to sputter and stall when engaged in gear.

 

[ntsqd]

No load on the engine when in Park or Neutral. In any gear puts a small load on the engine. Reving it in P or N just doesn't seem to tax the fuel supply system like putting it in gear can.

 

[Finally Mine]

Regarding the fuel filter, I also had no idea. The FJ started a little sluggish,but it did start. It was only until I was on the road and got up to 25-30mph did it begin. The fuel filter was loaded with rust, and once replaced ran fine. If it is truly the filter and rusted you may want to look at your gas tank which is where all my rust was coming from. Ended up replacing the tank. Good luck.