Alternator replacement -- resulting overcharging at 18 Volts ?!!

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Joined
Sep 10, 2021
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Hope everyone is having a lovely holiday season. I haven't been on this forum in a really long long time. Picked up a beautiful red well taken care of 95 miata for 1k recently and it's been having my attention! Miss being part of the community. I am back, and I am once again asking for your support on fixing my beloved LC xD

So, my 2002 LC has been not starting without a jump for a month now. I tested the battery under load and it was shot (estimated 531 CCA fullt charged). Third battery change in 4 years, thinking my alternator was slowly undercharging them over time. I monitor my car voltage actively, and it often dips to 12.x WHILE running. So, definitely weak.

Yesterday I drove it to the auto shop I work part time at, popped it on the lift. Put in my new reman Toyota alternator (P/N 27060-50260-84) from SF dealership (btw it was only $150 not including core, great deal right now!).

Installation was smooth (btw, happy to detail how I did it if anyone needs help). No problem with the connectors though I know it's often discussed here. Popped in a brand new Bosch 27F 840 CCA while I was at it.

Right after starting, I knew something was off. System voltage climbed, 12, 13, 14, 15, 16. The shop is .3 miles from my house, I drove it for maybe 15 minutes max. Turned it off, prayed that maybe my amazon-bought sensor was maybe off. No other signs of failure outside of my sensor readings.

Later that night, I started it again to move for street cleaning. Ran it for about 30 seconds. Immediately, voltage climbed again, this time to 17, 18, big danger zone. Car dash lights, headlights start flashing. Dash starts lighting up like a Christmas tree just in time for the holidays. See ABS,VSC trac, VSC off lights, though no battery or CEL light.

Now, I'm freaked out. High voltages fry electronics, irreversibly, first damaging little copper filaments here and there, and eventually over time will fry real wires and computers, start fires, that type of stuff. New battery probably also toast. Went to the dealership, they gave me another reman alternator under warranty, though they still wanted $900 for servicing it with them, so I left.

Has anyone had this sort of overcharging issue? Does anyone have any insight into whether the alternator is at fault and replacing it yet again will help me? My mechanic mentor at my shop thinks it's something else wrong with my car and not a "brand new" alternator's voltage regulator. I find that hard to believe because I've had zero electrical issues in the car for years.

I looked at the fuse box at the positive terminal which showed the alt-s fuse supposedly being there but when I opened the fuse box, there was no fuse in the alt-s spot.

Praying for some insight from y'all. Oh, and yeah I did get ticketed for street cleaning despite leaving a pleading note, damn those heartless SF enforcers : (
 
Oh, I didn't even think of that. I suppose I should try to bring the 2nd reman I obtained to an O'reilly's, I called and they have a machine. If its not that, you think it could be an open or failed S circuit?
 
The alt s fuse is the voltage sense wire for the voltage regulator in thr alternator. That fuse has to be there. Replace it and that should solve your problem.
 
Update: the alt-s fuse is indeed there and fine, I just didn't see it. I do think it is necessary for the sense circuit but it wasn't causing the problem. Nothing was wrong with the car before the install. The original alternator was, honestly, fine.

The reman alternator I got from San Francisco Toyota was just busted, as I suspected.

I took it out of the car and got it bench tested at the O'Reilly's right next to my auto shop. Fails voltage regulation. Pics below are of the test results.

I put in another second reman alternator (after testing it first) and now my car seems to run fine. Couple burned bulbs. I have this deep anxiety on the amount of electrical damage I've caused to my car.

Absolutely kicking myself for not testing the first alternator. But it was from Toyota. I thought I could trust them. San Francisco Toyota, as expected, refuses any concessions despite selling me a part that would have totaled my car if i was any less of a sensor-watching hawk.

Never install an alternator without testing it at your friendly neighborhood auto store.

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Wow, that really sucks but good you caught the overcharging before frying anything too major. Thanks for posting your experience here so others can keep this in mind, seems like a good idea to bench test a rebuilt alternator before install even with a Toyota reman.
 
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