so the other day my buddies 97 7.3 was having an issue staying running. the battery voltage guage on the dash showed barley 10 volts. we looked threw everything and found that 2 wires( the main and a smaller wire) both running to the alternator had been rubbed clearly inhalf on one of the pullies. we fixed them both and still nothing. so this morning we replaced the alternator and still it isnt charging the batteries!! so our question is what the hell else can it be?!

 

Did you check the rest of the wire for any wear/corrosion/damage? All the connections. Does that alternator also have the internal voltage regulator on it?

 

There should be a fusible link on that harness. I would check both wires with a volt meter! See if you have voltage with the engine off to the large charge wire. If not thats you issue and you need to trace it back.

 

well with the 2 wires that were messed up from being rubbed clean apart on the pully we just used butt connectors for a temporary fix. could this be our problem??

 

Well you redeemed yourself with temporary fix but ALWAYS solder. Some guys say butt connectors are fine but if it involves a circuit powered like that, solder. If its something for lights, quick crimping is fine.

May or may not be the problem. But definitely check over the wire. May be a missed problem.