alternator/ ground problem

[JohnZepka]

I've been having trouble with my all my lights flickering only when the car is running.  I recently switch from an alternator that used to have only 2 connections to a general alternator that has a seperate ground.  The new one has 3 places for brush sets.  2 that say field and one that says ground.  The ground one does not have a brush so I just connect the ground to one of the fields.  Is this my problem?  Another thing is that I have a solid state limiter that will cut out when it loses its ground, and that happens for a little while then the gauges will come back.  I will also get a surge of power and my lights get brighter from time to time. 

[JohnZepka]

Alright I figured a couple of things out and need a little help with a question.  I found I fried the smaller field wire from my alternator that goes to the voltage regulator.  Now I have a 60 amp alternator instead of the original 45 amp one, should I just replace that wire thinking it was bad, or is the 15 more amps creating this problem.  Also the regulator should stop any surge past that fried wire correct?

[A383Wing]

You don't say what year you are working on...but my money is betting you got a bad regulator if it's the 69 & earlier point style.....

[John_Kunkel]

I recently switch from an alternator that used to have only 2 connections to a general alternator that has a seperate ground.

You need to translate that, what is a "general alternator"?

The new one has 3 places for brush sets.  2 that say field and one that says ground.  The ground one does not have a brush so I just connect the ground to one of the fields.

You connected "the ground" to one of the fields? Where did "the ground" originally go?

Is this my problem? 

Probably, and that's what fried the wire. Don't just replace the wire until the hookup is verified.

[JohnZepka]

Sorry 66 charger.  It has a new regulator.  The alternator is just a common aftermarket replacement type of alternator and I hooked up one of the brushes to the regulator wire and another brush to a ground.  The fried wire is going into the regulator not after.  What I mean by hooked the ground wire up to one of the field wires is my origanal alternator had 2 wire hookups.  One was the bigger main wire and one brush that went to the regulator.  That's it.  It grounded through the smaller regulator wire brush.  At least thats what I think.  This one I had to add a ground wire and although it has 3 spots for brushes it only came with 2.  The 2 that are labeled fld both have brushes the grd does not.  However they all end up the basically same on the alternator. Thanks

[maxwellwedge]

First a 66 should have a single field alternator unless the voltage regulator was upgraded to the '70-up electronic and the 2nd field wire spliced in. 69 and earlier had two wires to the alt. The hot wire that connects to the threaded stud and one field slide on wire. I seem to remember you can run a dual field alternator on a pre '70 by grounding out the unused field connection but don't 100% remember for sure.

[JohnZepka]

Before I burned the regulator wire I had one wire to the threaded stud, one to the regulator on a field slide on, and a ground from a field slide on to the block.  If this isn't right on my 66 can someone tell me what I need to change, or if I need to add something different.

[maxwellwedge]

Have a look at this wiring diagram - it is for a 69 but the 66 is basically the same concept.

http://www.dodgecharger.com/forum/index.php/topic,55003.msg612962.html#msg612962

The wire sizes and color may be different though. I think the biggest problem is you have a '70 and up alternator with the dual fields. As I said earlier I sort of remember hearing or reading this is ok on a '69 and earlier if you ground out the un-used field connector but I am not positive....maybe someone else can chime in here.

The best bet is to get the proper single field alt or update to the the 70 and up style  electronic voltage regulator which will require some minimal extra wiring. There are some threads on that conversion on this site - do a search and have a look.

[JohnZepka]

Thanks for the diagram link Maxwellwedge however it doesn't really solve my issue.  I have a 66 diagram and it just shows the field connecting to the regulator like I had it hooked up.  All my electrical is in place like the diagram. I guess the only 2 things are maybe the field wire was bad or the replacement alt just doesn't work with this system being it does have 2 field connections.  One thing is if I hook up 1 field and don't ground the other I get no charge so it does need a ground. Any help would be appreciated before I just buy a new alt.

[A383Wing]

The dual field alt will work on the 66 Charger...all you have to do is ground one of the 2 field terminals and then hook up the other field wire to the remaining terminal.

If your lights are flickering, again like I posted above, sounds like the point style regulator is bad, I would suggest replacing that before another alternator.

[JohnZepka]

Thanks a383wing the regulator I have is new and the one before I had the same problem before it went out.  Could it be that the field wire was bad all along and/or maybe the regulator points need adjusting.  However if it was just a regulator adjustment it shouldn't have fried the field wire.  Right? I do have 15 more amps out of the new alt from 45 to 60 does that make a difference?

[John_Kunkel]

The larger amp rating of the alternator won't affect the field wires or the regulator.

It is perfectly OK to ground one field on a two field alternator for use on a '69 or earlier system, if doing so causes the other field wire to fry the alternator has an internal short or one field terminal isn't properly insulated. Try switching the regulator field wire to the field terminal you now have grounded and hook nothing to the one you now have the field wire connected to.

If this allows the system to work properly the one field terminal is shorted to ground.

[JohnZepka]

Thanks for everyone's help, I'll be in the garage tomorrow and I'll see where I end up.

[71_deputy]

with the two wires off the field terminals I would check each to case ground- should be no reading- if so- field coil is grounding to case somewhere!

this could cause the field wire to burn up!- it gets 12 volts from the voltage reg. on the single terminal alt's.