Electrical Gremlins - Need Input

[cruiser4life]

1997 80 Series. 158,000 miles.

Less than 2 years ago I was traveling on the highway and the red warning light (system discharge light) at the top right of the dash gauges came on and my electronics started acting weird. Turned all electronics off and proceeded to my destination. After turning off the truck, it would not restart. Checked / searched here on Mud in other threads and the feedback was that the brushes in the alternator needed to be replaced. I had it towed to a dealer where I was and just had them put in a new alternator. Short on time and wasn't a place I could wait for the brushes and do it myself. No problems for a while...

Fast forward 1 year and same thing happens. Light comes on, I get where I am going and won't restart. Had it towed to my local dealer and they said the replacement alternator above had issues and they replaced it at no cost.

Fast-forward 6 months and light comes on, I park right away, wait until the next day, it starts and no problems observed moving forward.

Yesterday I am driving and the red light comes on. I pull over and check the alternator, battery connections, etc. All connections are solid. Called for a ride and turned off the truck. Wouldn't restart. Had it towed to dealer.

Dealer says the system is charging fine (though the warning light supposedly means the system is discharging). They say that I just need a new battery.

I trust my mechanic at the dealer (friend of mine and fellow cruiser enthusiast) but I am not sure there isn't more to this than replacing alternators and batteries. It's been a while since the battery was replaced so no worries there but I am not confident that will take care of the overriding issue that keeps leaving me sitting, waiting for a tow.

Any similar experiences or ideas???? Thanks in advance...

 

[elmariachi]

You haven't said how old the battery is but if they have load tested the battery and its bad, then its bad, regardless of what has happened before. Typically the charging issues with these trucks are either the battery, the alternator, or something draining it and you don't speak as if you have had that problem.

 

[PabloVTA]

yep, happens to me too. Thought it was the Starter contacts or the Alt as well.
had a new alt put in too, still did it.

then I checked the cables on the alt. Seems that Chuy the grease monkey liked to persuade the oil filter off with the tact of a bull in a China shop.

you might want to look at that as well.

Was it raining when these happen?
what kind of electronics do you run as assesories in your rig?

 

[cruiser4life]

Thanks for the feedback.

Did an entire starter replacement not too long ago as well, so after the battery is replaced that will be battery, starter and alternator all replaced within the last year.

No, it was not raining in any of the situations above. All cables seem secure, tight and clean. Checked that yestersday...

As far as accessories and other electronics, nothing other than stock items - CD, radio, lights, etc. Nothing aftermarket at all and nothing is ever left on after the ignition is turned off.

 

[cruiser4life]

You haven't said how old the battery is but if they have load tested the battery and its bad, then its bad, regardless of what has happened before. Typically the charging issues with these trucks are either the battery, the alternator, or something draining it and you don't speak as if you have had that problem.

Didn't do a load test but it's a knock off battery from the PO that's at least 4 years old. Can't hurt to put a newer, stronger one in anyway.

I think both the Yellow Top and Red Top are overkill as I don't have any aftermarket accessories but even the stock Toyota batt they are recommending is much stronger than the one in the vehicle now.

Anyway, I am doubtful this is the end but new alt, starter and battery should help...

 

[Tools R Us]

Toyota alternators are pretty durable, I could see one dying, but this seems like a reoccurring problem and that's not right? The first thing I would check/clean is the ground system, starting at the battery, the ends of the ground battery cables, then the ones from the engine to frame and body. I have seen a poor ground connection cause the regulator to make the alternator run at full output all the time greatly reducing it's life. By clean I mean remove the bolts and clean the contact surfaces with a small wire brush or fine sandpaper until shinny.

 

[Rich]

Also could be a damaged internal connection between the battery post and the battery plates. Often due to someone hammering a battery cable clamp down on the battery.