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Rebuilt doesn't always mean rebuilt correctly. Swing by NAPA and have them check the alternator. If you have to swap it out again have them bench test the new one before you install it. I've had issues with rebuilt alternators before.
Look on the bright side. At least this is an easy part to change.
I fixed the problem by replacing the connector on top of alt. The small wire was broke
inside insulator right at the connector.
Thanks for all your help.
Monroe
Check the harness going to the alt. where it runs behind the battery. on mine the big wire from the alt. has a splice there and it was corroded into.
I see you got it never mind.
I had the same problem with my 99 250 SD diesel and after going through three alternators, I found a broken wire in the harness over the left rocker cover. If you can't find the problem, this might be a place to start.
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