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Terminals being the studs on the batteries or the end of the cords?
Clean the terminals on the battery's and the connections on the cables. You need a meter. Mine would sit around 12.4 volts with the vehicle off. Running I see 14.2.
Well I tested my batteries and they are both showing 13.0-13.7 with the truck off. The connections are all tight, no play when you wiggle them. Corrosion is minimal.
My arms are fairly large too, and I don't have any problem getting the belt off or on my truck. Its size makes it pretty easy to manipulate (with a little patience, of course).
The regulator is internal to the alternator. You can have the alternator tested at pretty much any of the big box parts stores. I'm not 100 percent convinced there's a problem with it; I'm kind of wondering if there's a loose wire somewhere, or if somehow the glow plug relay is energizing briefly for some reason.
It's a shame you aren't closer to Grand Haven if you do need to replace it. There's a shop in Coopersville (or maybe Nunica) I had great luck with for starters/alternators on my old boat when I was there. The place wasn't much to look at, but they were very helpful, and turnaround was quick.
Well I got the alternator tested and batteries tested at O'Riellys this afternoon. Both batteries were bad. Alternator was 100% good. So bought 2 MotorCraft batteries. Truck seems extremely happy!
This morning the truck fired right up but got down the road and watched my voltage meter dance and headlights dim.... It's a huge range it looks like 14volts, normal, up to over 15...
The dimming lights stopped and when I got to work all of 7 minutes ago, sitting in the parking lot I flashed the brights on voltage gauge dropped, flicked em off and went back up.
There is one connection at the batteries I may need to double check since installing new batteries. But what else could this be?
That 13 to 13.7 volts on a sitting battery was way too high... I can see why the batteries checked bad. Your alternator should not charge any higher than about 14.7 volts. I wonder if the regulator is going too high and whittling away at your new batteries, if the battery cables worked their way loose, or if you have a loose connection on the opposite end of the battery cables or on the alternator.
Well the thing is with local auto shops like O'Riellys, Advanced, and Napa, they all have one thing in common..... The supplier send them the wrong regulator.... Wrong connector and made for a bigger amperage alternator....
Like I said the alternator tested fine..... The last thing I need is to have these batteries killed too. I will be double checking that connection when I get home.
Whatever it is, it seems to be intermittent. That can be heat related (you won't easily duplicate that on a test bench) or vibration related... as two possible clues to the root cause.