Found my drain! Alternator!?!?!?!

[gsniegow]

Overnight I managed to catch, finally, what I believe has been draining my battery each night.

I caught my alternator drawing 4.3 Amps of current.  I was able to verify (in my mind) that it was definitely the alternator because it was VERY hot to the touch as well! 

I had installed this alternator back in March / April, it was the PowerMaster 175191.  ( http://www.powermastermotorsports.com/mopar.html )

I added two electric Spal fans which do draw allot of current.  I'm NO expert on any of this stuff, but if my car requires more current then the alternator can provide, will that somehow damage my alternator?  (I had also installed a stereo / Amplifier a few weeks earlier as well)

I was thinking of upgrading to the PowerMaster 8-47529 which states it can put up to 140 Amps out.  (I realize at idle that number will be lower)  Does anyone have any experience with this alternator?  Their website states I might need to make slight bracket alterations?

I have made the following electrical changes as well.
* Ran a wire from the alt to the starter relay which will then feed the battery.
* Removed the leads from the Ammeter and connected them to bypass the Ammeter.
* Installed new engine bay wiring harness

IF I go with this more powerful alternator, are there any other areas of concern in hooking this up?

Thank you in advance! 

- Gene

[John_Kunkel]

I have made the following electrical changes as well.
* Ran a wire from the alt to the starter relay which will then feed the battery.

What size wire? For 140 amps you would need at least a #6 wire and the wire leading from the relay to the starter lug is often only #12 or #10 so that needs to be upgraded to #6 also. Since the ammeter is bypassed, I'd run a #6 (or larger) from the alternator directly to the battery.

[gsniegow]

Currently I have a 10 gauge from alt to starter relay and down to the battery.

Are you suggesting to go from the alt straight to the battery with 6 gauge, bypassing the starter relay?  Then leave the 10 gauge from the battrery to the starter relay?

Sorry, not an expert or even a novice on this! 

[Chryco Psycho]

I would not use a power master ! Maybe a Denso , Mancini has a conversion kit

[gsniegow]

Chyro - Is there a reason why not PowerMaster?  I have been told that it was a high quality alternator???

I will check out your suggestion when I get back home. 

Regardless of brand choosen, are there other areas I need to worry about?  Was my understanding on the 6 gauge correct?

[Chryco Psycho]

I have nothing but problems with Powermaster products some have lasted as long as 3 days , I would avoid them .
Running a 6 ga wire is no issue , too big never hurts , running a wire that is too small may not cause a problem until the alt is forced to put out full charge where the wire becomes a resisitance & causes the wire to heat up & melt / short .

[b5blue]

  Get the Denso and don't look back. @ 60-80 amps output @ idle (depending on idle RPM) and 120 amp max it will feed you stuff the power it needs, when it needs it, the way it was designed to get it. The car's engine will run better not starved for power, your battery will thank you as all it will do is start the engine.
  I'm on year 3 with mine, no issues, bright headlights, fast wipers and blower. This with no mods to harness. Mancini's kit comes with a Denso Factory re-man unit so it's built right. You can feed your high draw items directly from the output stud.
  I've yet to figure out why everyone is trying so hard to "back feed" their vintage Chrysler power systems with GM units made for systems designed for one wire alt. charging?  Why run everything off the battery needlessly?

[John_Kunkel]

Are you suggesting to go from the alt straight to the battery with 6 gauge, bypassing the starter relay?  Then leave the 10 gauge from the battrery to the starter relay?

Yes. If you run the #6 wire along the core support it isn't too unsightly.

[Charger RT]

I ran my extra wire along the factory harness. Right back to the firewall along the firewall to the booster area then to the battery. I used black wire to hide it and I strung it along the bottom of the harnesses along the way. I avoided using wire tie but instead used black tape to hold it to the harness. It almost invisible.
Tim

[Fred]

I have a question...........
By connecting a #6 cable from alt to battery positive, aren't you running the risk of over charging the battery?

[macca3441]

Hey Fred,

In answer to your question....no!
By connecting a lead (provided it's a heavy enough lead) directly from alt to batt, reduces any chance of voltage drop occurring throughout the circuit.
When an alternator is replace on any vehicle with some age on it, I always recommend a new main power cable be installed in addition to the existing one.

Wade

[Fred]

Hey Fred,

In answer to your question....no!
By connecting a lead (provided it's a heavy enough lead) directly from alt to batt, reduces any chance of voltage drop occurring throughout the circuit.
When an alternator is replace on any vehicle with some age on it, I always recommend a new main power cable be installed in addition to the existing one.

Wade

Thanks for that Wade.  Gives me something to do instead of just twiddling my thumbs.

[gsniegow]

Thank you all again for your help!

I have been looking for this Denso alternator and have not been able to find one.  I have searched several web sites including Denso's and I can not find any results for an alternator for a '69 Charger w/383.  Would someone mind sending me a link?

Thank you again!

[Chryco Psycho]

Mancini should have the denso conversion , mancini lists this one PWM8102 on this site but it is a powermaster too , or check with 440 source http://store.440source.com/Alternators-Brackets/products/64/ part # 122-1004

[b5blue]

No the link is to the 60amp alt. you need the 120. My kit from Mancini included a Denso #210-0138 remanufactured alternator. Call Mancini!

[Nacho-RT74]

I JUST replied your PM and now read your success... sorry I have been REALLY REALLY BUSY latelly.

[gsniegow]

Nacho - Thank you and no worries!  Here is my latest update...

SO my friend told me that PowerMaster will test, repair, or replace the alternator for me as I just purchased the alternator at the end of March.

Lucky for me, they are located in West Chicago, IL which is only about 25 minutes from my employer.  So yesterday over my lunch hour I ran the alternator over to them.  It appears that I had some corrosion by the electrical connections.  They explained to me that the corrosion does conduct electricity and they believe that the corrosion was causing the voltage regulator to kick on.  They cleaned everything up and replaced the diods and voltage regulator just in case there was damage there too.

I know there has been some negative views towards PowerMaster.  I can not speak to the quality of their products at this point.  My corrosion was due to a heater hose that blew and spewed anti-freeze everywhere.  Looks like the issue was one that I inadvertantly caused.  I CAN say I was very impressed with the attention that I was given while I was at PowerMaster.  First - I emailed them on the Monday before the 4th.  Their shop was closed all week due to the holiday.  A gentleman by the name of Tommy responded to my email while he was on holiday!  When I arrived yesterday at PowerMaster an individual in one of the two offices I saw came out and greated me.  He brought me to the shop and put me in touch with one of their technicians.  He left while I explained what I saw happening.  I was routed back to the office area to wait.  While I was there that gentleman followed up with the technician and came out to talk to me further.  We spoke about my car, other issues they have seen with Mopar's, and likely scenarios that can cause corrosion.  Even when a sales call came in, he stayed with me making me feel like I actually mattered to him.  Finally the technician came out with my alternator and gave it to me, no charges what so ever!

Anyway - I installed the alternator yesterday and all seems well.  Thus far, it made it overnight without any real voltage loss from the battery.  I can not remember the last night that passed without draining my battery.  So it looks as if the corrosion was my issue.  I CAN NOT explain the time factor that was taking place.  Why every night in the over night early morning hours this would occur, but at this point I'm happy to see the issue MAY be resolved.  Will see how the next couple of days go!

Thanks again to everyone who offered their help!   Hopefully one day I can return the favor!