SOLVED: 100 Series overcharging issues (1998-2002 charging setups) (1 Viewer)

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cruiserpatch

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This has been documented on a few other threads but I figured I would add a definitive OEM solution for this problem.

Background:

A few weeks ago my mother's 1998 LX470 started up with an illuminated battery light. I the volt-meter in the cluster read 18V+ so I used the spare tire kit (there's a 12mm/14mm wrench in the kit) to remove the serpentine belt and drive home.

The next day I swapped out the 4-month old Autozone alternator to a spare Denso rebuilt unit I had lying around. Same problem. I tested the battery and found it to be good (also only 4-months old).

I was discouraged because I wasn't sure where to start next until I found this thread (specifically post #6). I swapped the ALT-S fuse but it did not solve the issue. Still cranking out 16V+ at the terminals with the engine running.

Then it occurred to me that I could swap some parts off my own truck and see what might happen. Sure enough upon disassembly of the N+ fusible link block, I found evidence of age and corrosion enough to increase resistance across the ALT-S circuit (and probably more than just that).

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Above^ 1998 LX470 fusible link block assy.

Solution:

I replaced the entire N+ Fusible link block using these parts (available on cruiserpatch.com):
  • OEM Block assembly, fusible link (1x): 82620-60010
  • OEM Block assembly, fusible link cover (1x): 82621-60010
  • OEM 100A fusible link, blue (1x): 90982-08246
  • OEM 140A fusibile link, maroon (1x): 90982-08286
  • OEM 7.5A "ALT-S" mini fuse, red (1x): 90080-82020
  • OEM bolt with washer (6x): 90080-11224
I also replaced the following: (cruiserpatch.com)
  • OEM N+ battery terminal (1x): 90982-05035
  • OEM 12mm conductive nut (1x): 90179-08053
  • OEM alternator connector: 90980-11349 (cruiserpatch.com)
On my personal truck (1999 LX470), I'm running an X2 Power AGM battery so I use this GM diode instead of the 7.5A 'ALT-S' fuse (this increases voltage to 15V max at idle).
  • GM 12135037
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Above^ 1999 LX470 with X2 power AGM battery and fusible link block assy. removed
 
Voltage with battery light on (original fusible link assembly): 16.8V

Voltage with 1999 LX fusible link assembly (swapped from my truck): 14.4V

Voltage with brand new OEM fusible link assembly and N+ terminal: 13.83V

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