Ok guys, I have alternator issues, sort of. I bought a 'Quickstart' alternator, 160 amp and have had to send it back twice for issues. The first time they replaced something, rectifier I think, and sent it back under warranty. No problem. Now, my battery light comes on. At first it was seldom and sporadic but now its all the time, on and off, and usually at any RPM above 1500. I checked it with my volt meter and it does stop charging when the battery light is on. So, I sent it back again. They tested it, or so they said, and didnt find anything wrong with it. They proceeded to tell me that my truck had wiring issues and its my problem. Heres the rub on that, while they had that alt, I put a new OEM unit on it and never had an issue....no battery light, ever and with my power point meter, it never stopped charging.

So, last week, I decided to have a look at my wiring. I checked all grounds, all B+ connections, all fuse links, did several and severe wiggle tests and nothing seems to be wrong with the wiring.

More info and a couple questions: The QS alt has a larger body, therefore I had to shim it to clear the alt bracket. Could I be losing the case ground this way? I was thinking I should run a separate ground wire from the case to the block. I was also thinking about a larger charging cable from the alt to the battery. Or, maybe the charging is shut off when it gets to a certain level?

Looking to fix this issue with the alt I have, if possible, so I dont have to buy another one. Any help is appreciated. Thanks.

 

Get a DC Power alternator. I kept having issues with the alternator going out all of the time under warranty so I bit the bullet and have not had an issue in 3 years. They cost more but more than make up for it with peace of mind

 

Check your grounds from the engine to the body/frame. They tend to corrode, I went from the alternator directly to the negative cable

 

I would try this first and see what happens.