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Re: warning lights flickering while driving[200/83] posted by Dave Stevens on
Saturday, 29 May 1999, at 1:45 a.m.
A few thoughts to get you going on your charging system problems:
a) Check the small red wire field activator connection on the back of the alternator. It's a push on female connector inside a plastic shield. It's real easy to push this back on so the tab is between the plastic and the outside of the connector. This can give sporadic problems such as yours. Make sure that conection is snug. Did this to myself only a few days ago.
b) Despite what the alternator shop said, remove the brush assembly from the back of the alternator. Exposed brush length out of the holder should be min .5" (as I recall without looking in the book). Any less may give a weak or intermittent contact. The symptoms will be poor charging and flickering dash lights. Replacement brushes can be soldered in or you can get a new brush assembly (see next note).
c) Your car may still have an external voltage regulator and it may well be weak and not capable of pulling a full load from the alternator. With a full electrical load (all lights/fans/heaters) and at fast idle you should be seeing more than 12.5v volts at the battery, preferably 13+ volts, otherwise the battery isn't getting charged. If not, consider replacing the regulator with the newer combined regulator/brush assembly.
d) The wire harness to the alternator goes under the crank pulley. What with heat, oil and possible abrasion it can easily become brittle and/or damaged. If only a few strands are connected or if the wire insulation has flaked off allowing a short to ground then you can have charging problems. Wire harness rot often affects this area first. Check your wiring and insulation.
e) Check/re-make you battery negative connections -at battery, block and chassis and the battery positive connections -at battery and at distribution block on left fender. Check you fuse panel for signs of corrosion.
f) Snug up the alternator belt, but not too much, just enough to avoid slippage. Belt squeal may be a sign of slippage, but it can also be a sign of mis-aligned belt pulleys and a glazed belt.