Author	[Modern View]
JimS 10-29-2012 14:06:25 209.148.97.97 Report to Moderator	I have a 1990 Dodge Diesel truck. For some reason, the charging system only seems to last about six months (this has happened at least 4 times). Around that time, the voltage regulator (which is a separate unit) fails, the alternator over charges, and the battery blows up, literally. I have a good rebuilt Bosch alternator, or at least the best Pep Boys has (I know, but I was next to one when it failed). I got the best voltage regulator Napa has, and I have the stoutest Die Hard that they sell (again, I know, but there is always a credit on it for replacement). I am most suspect of the regulator. One time when this happened I had to install three before I found one that worked. I understand the regulator will handle an overcharge of about 14 volts, any higher and it fails. What I cannot figure out is why the alternator keeps over charging (an independent shop says it is overcharging and so does Sears, but they say it is a little over. Pep Boys insists it is fine). Can anyone suggest anything else that may be the problem? I cannot imagine shorts causing an overcharging problem, in fact it should have the opposite effect. Thaks for your help; JimS [Reply]   [No Email]
MSM 10-29-2012 15:37:13 75.192.166.255 Report to Moderator	Re: Overcharging system in reply to JimS, 10-29-2012 14:06:25   The regulator grounds through the case to the firewall, is most likely loosing it's ground. Make sure you have a good clean area(shiny metal) where the regulator bolts to the firewall. I would also run a separate ground wire from one of the regulator mounting bolts to the engine block or to the negative battery terminal. [Reply]  [No Email]
JDseller 10-30-2012 18:15:26 208.126.196.144 Report to Moderator	Re: Overcharging system in reply to MSM, 10-29-2012 15:37:13   MSM has half the problems solved. You need to run a ground wire directly from the regulator to the alternator. Then go to a good local alternator repair shop. The one I use is: Sheehan Auto Electric, 395 Desoto Ave, East Dubuque, IL. Tel: 815-747-6110. They have a much heavier regulator. It will cost about three time the what the cheap one cost but last for years. I have a 1990, 1992 and 1995 Dodge diesels. They all had the issues with the charging system. After I installed a separate ground wire and a good regulator I have not had any issues with them. [Reply]  [No Email]
Ralphwd45 10-29-2012 15:32:39 66.243.226.232 Report to Moderator	Re: Overcharging system in reply to JimS, 10-29-2012 14:06:25   I don't know anything about the newer Dodges, but the Dodge pickups that I have, and have had, were from 1972 to 1980. They will overcharge, enough to blow out 12 vt headlight bulbs, and the only cure was to change ammeter units, or remove ammeter and put a screw and nut thru the two ammeter wire lugs, and make sure they were darned tight! I have had 3 trucks burn up the wires terminating at the ammeter, and ruining the ammeter unit. [Reply]  [No Email]