Rebuilt Stock IC Alternator: Truck Will Not Start

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Joined
Nov 2, 2022
Threads
41
Messages
128
Location
Virginia
Got brushes and bearings from #CruiserMatt. After doing that job and reinstalling said alternator the truck will not crank. The gauge shows voltage; the battery is at 13.5v on my meter. Nothing. Gauge drops to zero when I turn the key.

Not well versed on this type of job but per the FSM I have:
- greater than 2v at regulator terminal L
- around 12.5 at terminal B (switch off)
- over 12.5 at the harness side of the alternator terminal IG
- engine and charge fuses OK

Part 27387-45022 that goes on terminal B cracked during reinstallation. I put a plastic washer in its place. Without that, when that wire makes direct contact I think it is causing a short?

One regulator terminal bolt stripped; terminals F & L have bolts but the last one on the right does not at this time.

CleanShot 2026-05-16 at 17.28.35.webp
 
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