2nd Gen Non-Engine/Transmission Alternator/Tensioner/charging issues....

[CCiatteo]

Saturday I was coming home from Home Depot and notice my GEN light was on. I had never seen this light before, I quickly checked the gauge and sure enough the needle was hovering on the danger zone 11 volts+/-. So I get home and assume (I know, I know) its the alternator. I start digging on here for info, come to the conclusion that I need to get a new one or have mine rebuilt. Sunday being mothers day I figure a new one is my only shot. I find one, and pop the hood to take my old off and bring it with to match up (just to be sure) and notice the belt is slack? Turns out the tension/idler is dead, I can move it with my hand easily in both directions. That's good I figure, its not the alternator.



Today I pick up a new tensioner/idler assembly (dealer wanted $225 and day's wait) from Napa for $75. Install it, fire up the big Dodge and all looks well, gauge returns to 14 volts+/-. A couple miles down the road I hear (over the roar of the engine, windows up) a squealing noise. I turn around and head back home, by the time I get back home the squealing is gone, and now my volt gauge is reading 11 volts+/- again. I pop the hood with everything running to make sure the belt is tracking properly, no pulleys are frozen or crazy stuff. I get out my multimeter and check battery voltage at the batteries, both are reading 12. 26+/-, rpm has no effect on the reading.



Thinking back, after turning around I had the windows down and thought I smelled something burning, very very faint, I was in traffic and wasn't sure of the source, maybe it was me???



Is it coincedence that my tensioner/idle died at the same time my alternator appears to have died? Or is there something else going on here?



Batteries are Red Top Optima's less that a year old, so I'd like to think they are ok. Cables/terminals are clean and in good shape (that boeing shield stuff works great). Prior to Saturday afternoon I had zero charging issues at all. Tach works fine, so I am leaning away from CPS.



Bad luck and coincedence or is there a bigger problem. I don't mind putting a new alternator on a 12 year old truck with 209k, but would hate to burn it up if there is something else at play.



Thanks

Chris

 

[B.G. Smith]

Inspect the belt, the ribs in the belt should not be bottoming out in the grooves in the pulleys, may be slipping if it is bottoming out. bg

 

[DPrew]

I had to replace my alternator a few weeks back because the check gauges light came on and the voltage gauge showed nothing. When I got home and popped the hood there was smoke coming out of my alternator.

 

[CCiatteo]

Well the final verdict is in. The alternator was toast, now if the tensioner had something to do with this, I doubt it. My volt gauge was giving signs in the weeks leading up to the failure, upon start up I would notice it would take a couple minutes for it to reach full charge. In the winter I'd expect this, but not this time of year. I chose to have my alternator completely rebuilt by one of the local shops rather that risk a reman or wait for a new one to arrive. I also had to put on a new belt because when the tensioner died the belt must have gotten glazed from the crank pulley or something because it was squealing really bad, even after the new alternator and tensioner. I swapped in my old belt that I had in the cab as a spare and all the squealing went away, so a brand new belt will go on tomorrow.

Total damage = fully rebuild my alternator $150, new tensioner $75, new belt $35 = $260 and I'm back on the road with confidence.

Batteries now read 13. 65 at idle..... woooohoooo