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Got my truck back from the shop after replacing the HPOP. The CEL kept going on and off and the voltage/chargeing system was low. When the CEL comes on engine runs rough and truck shifts hard.
When the CEL is out truck runs fine. Thought maybe not enough electricity to carry everything. Found a cracked positive batt cable replaced, still low charge Batteries at 12.4 volts, started truck checked for voltage running still 12.4 volts.
Pulled alternator took to Azone killed thier test machine everytime they spun it up. Installed new alternator on truck, every time the charge needle moves to show charging kills truck?
Do you have a DC volt meter to check out put at idle and say 1500 RPM? If batteries are not up to full charge, charge them and then load test. Batteries must be in good shape, Alt. must put out 14.2 and steady, not erratic. I just changed mine on the '96 and after 1500 RPM it was erratic and caused the truck to misfire. My son and I went through 7 alt. from 4 different Adxxxx and Auto junk stores ONE night on a rice grinder grocery getter. I'm not exaggerating.
It sounds like the shop that put on the HPOP owes you some money. You need to start keeping all the receipts for this and have a talk with their manager when you fix it. I'm sure they had a fast charger on it to try cranking the engine and they probably did it for a LONG time. Check the cables going to your starter. I bet they got really hot and possibly melted. Maybe when the alternator starts charging it's getting a short to ground from the cable down there. Powerstrokes don't run with no juice like the old diesels can.