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Old 02-20-2013, 03:53 PM
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What size wire do you have running to the large stud on the alternator.
What is the charging voltage.
Dont rule out a defective replacement alternator, if it is an Autozone etc rebuilt there is about a 20% chance it is junk. Before you kill yourself chasing wires, pull it and have it tested.
Your wiring sounds ok if the wires are actually going where you think and have good connections.
If this is an 10si style alternator there is a hole in the back that has the regulator tab exposed. If you short this regulator tab to the case of the alternator it will cause a healthy alternator to put out at max rating. The hole is d shaped. See pic below. A small flat blade screwdriver will work perfect.
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