Back again.

This GMC is the gift that keeps on taking.

Previously we had an intermittant issue where it would charge fine... then the battery light would come on, the voltage on the cluster gauge would show low at 9v & often the gas gauge would show an empty tank and temperature would show cold (regardless of engine temp). Kinda sorta figure that's all cluster related...

Sometimes it actually would not charge (measured with a dvm) while other times it would charge and show 14.5v even if the cluster showed a low battery light & low voltage.


Fast forward to tonight:

• Alternator is not charging again. Engine running had 11.5v measured at battery with dvm so...
• battery is dead as a doornail. Voltage never came up even with jumper cables to running vehicle
• ALL gauges (EXCEPT oil pressure) are showing low
• the gas gauge also shows empty but has half-tank gas just put in

Questions:

• The intermittent cluster issue... is this something that's semi-common? If so - what's the 'fix'?
• I downloaded the article to convert from PWM to battery reference... which was recommended to be done but the URL for parts listed (pcsconnectors.com) is kaput. Is there another place that has this stuff without paying more than a new alternator costs?
• Which brings me to question three: Are there any alternator upgrades that bolt in & plug in without modification? Nothing to power amps etc - just something that will charge an effin' battery reliably without breaking a sweat.

 

Well - overnight charge on battery, reconnected & all gauges showed 'ok'. Drove to AutoZone for load test & alt. test and both tested 'ok' but manager immediately wanted to know who installed battery (her store or another location) & pointed out they had put those felt anti-corrosion washers on the cables on the battery.

(DON'T use these felt washers on side post batteries! --> http://amzn.to/1OtCCHb )


In retrospect; it's something that I should have caught and removed myself.

The side post battery cables must be flat & flush to the battery terminal and those felt washers can prevent full contact if any of it is caught between the cable & the battery terminal irregardless of the bolt being tight.

Manager said that this issue had fried another customer's alternator while also having intermittent charging problems.

We'll see... as with anything intermittent; it never shows up when you're testing for it.