After running a cable directly from the front power distribution center to the starter bypassing the fusible link, it shut off while driving.

Tiny
RICKT76
  • MEMBER
  • 2006 DODGE CHARGER
  • 5.7L
  • V8
  • TURBO
  • 2WD
  • AUTOMATIC
  • 500,000 MILES
Hi,

The car listed above is a police pursuit model. I'm having an issue tracking down a short and the alternator not charging the battery. I've replaced the alternator twice, the starter once and the battery. I bought the car with bad heads knowing it was going to have to have the heads replaced, not knowing the extent of the damage, had to rebuild the whole motor. Now I had a no start condition at first. So, I ran a cable directly from the front power distribution center to the starter bypassing the fusible link. Then started the car and it ran great on my way to work then when I went to leave got 2 exits down the highway and it shut off. The battery was drained, and all the issues started from there. I guess the voltage regulator was blown so I replaced the PCM. $500 later it ran great for about 20 minutes and the problem persisted I guess the regulator in the new PCM blew. So, I got an adjustable external regulator and bypassed the PCM regulator all together. The brand-new alternator still won't charge over 10-volts no matter how high I crank up or down the resistance on the regulator. I have been working on this car for the last 6 months and am about to throw the towel in. Any help would be greatly appreciated!
Thank you,
Rick Thomas
Sunday, June 25th, 2023 AT 11:10 PM

1 Reply

Tiny
AL514
  • MECHANIC
  • 4,119 POSTS
Hello, this system is not controlled by resistance, it is controlled by a pulse width modulated signal on the Gen Field Control circuit from the PCM. Take out the external regulator, which is only adding resistance to a wire that you are probably shorting to ground. The PCM also varies the amount of charging control based on the Ambient temperature sensor, there is a fusible link on the red wire that goes to the Starter and off of that stud the wire runs to the Battery, Ill post a diagram of the circuit. The PCMs Gen field control is around 250Hz pulse width control, but it will change depending on electrical load. But you should also check that the ambient temperature sensor is working correctly too, if its outputting incorrect signal the PCM will change the charging system output based on that temperature. Ill post a circuit of that too,
This Ambient temperature sensor is wired into a control module that is on the one of the data bus networks in the vehicle, you should be able to check its output with a scan tool on the PCM live data PIDs, To check it, if you unplug it there should be 5 volts on the Signal wire while unplugged. The other wire is a Ground, but to check the data bus you would need to use an oscilloscope to see the network transmitting data, so it's just easier to check the PCM live data and look for the Ambient Temperature sensor, it will most likely read a voltage and an outside temperature.
Now, you added an external voltage regulator, so I don't know how that is wired up, if you ran a resistor between the Gen Field Control wire and to Ground, it most likely overheated the Alternator and possibly the diode trio inside. So, when you get things hooked up correctly, you should check for any AC voltage ripple coming out of the Alternator. It should be less than 50mv at idle, some allow for a little bit higher when there is more electrical load, but at this point it's difficult to say what has burned out by now.
You should do a voltage drop test from the red wire post on the Alternator to Battery positive at idle and see how much voltage is being lost on that wire. Do the same for the negative side of the circuit, from the Alternator case to Battery negative.
To see the 250Hz control signal from the Alternator you would also need a scope for that, but there should also be live data from the PCM for that on a scan tool.

It wouldn't hurt to verify the engine grounds to the battery negative as well, seeing that the engine was out. Check it the same way at idle, from the engine block to the battery neg, and the body to battery negative. There should be very low voltage reading, below a 1 volt. You might be missing the chassis or engine grounds. This would cause the PCM to lose it grounds as well.

https://www.2carpros.com/articles/how-to-check-a-car-alternator

https://www.2carpros.com/articles/how-to-use-a-voltmeter
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Monday, June 26th, 2023 AT 9:37 AM

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