I have been searching for an answer via forums and google and can't anything matching my issue. I apologize in advance for the lengthy post but I am going to give the back ground from the start to now.
Truck info:
1994 Dodge Ram 1500 4x4
5.2L V8 no mods
NV3500 Manual Trans 5-speed manual
Aftermarket goodies:
2 35Watt HID lights
5 100 Watt KC Daylighters

At the beginning of December I was in Northern Arizona for a hunting trip, one night on our way back to our cabin my truck started having power surges (dash lights would flare bright then back down randomly) thats when I noticed my volt gauge was reading around 16 volts. Well I kept going down the road keeping a eye on the gauge figuring it was that high because I was running all my Lights (5 KC 100 watt, 2 35 watt HID, then 55 watt headlights) with a 75 amp alternator (plan to up to a 120). After getting a little farther down the road my lights started cutting out, the HIDs flickered then died and the KCs just dimmed and then the truck threw a CEL (never got the code). I pulled over and shut all the lights off for a minute and then turned the headlights back on and nothing else. Made it back to our cabin and turned the truck off and then turned the key back to on and nothing, no power to anything. Next day got it jump started and it ran everything fine, no CEL just the battery was dead and once turned off wouldnt restart without a jump. Left it alone until it was time to head home, jumped it and headed down the hill towards home, this time the entire trip home the volt gauge read around 16 and worked down to 15 volts, just before I got home the truck threw another CEL and when I got it home and turned it off the battery was dead again. Replaced the battery and everything was good again, kind of, still reads 15-16 volts colder it is, used a multimeter and found the alternator is pushing 14.5 at idle. Now about a week ago it threw another CEL which I didn't catch and when I turned it off and then fired it back up and the entire system reset like the battery was disconnected, stereo reset, computer, everything. Then it was fine. The other night was out off roading with a friend and I had everything running again and volt gauge read 16 (I was getting used to being that high all the time no matter idle or rev'ed up) I came to a stop, let the clutch out to start rolling again and it stalled out, everything shut off except the KC's and the truck reset again like the battery was disconnected again, no CEL this time. It did this to me twice that night. Then last night I was out with family in the desert for our Christmas party and sure enough it did it again when letting out on the clutch, I kept thinking that I just wasn't give it enough fuel to get rolling but everything shut off and reset, fired right back up and kept going. Got it home and was sitting in front of the house about to pull in the driveway and it did the same thing again, wasn't running any other lights besides headlights and was going to pull in and leave it running so I could get the scan tool I borrowed when it died.

Now every time the truck would die like this I just started it right back up with no issues. The truck wouldn't run any differently, just stall out or reset when I turn it off. I know I am pushing my Alternator when I run with all my lights but that isn't very often. When I searched I read a lot of stalling issues that were IAC, TPS, O2, sensors like that but I didn't read any where the truck resets itself. This problem is intermittent, But I can't recall a time where it did it to me with the engine being cold or right after start up, the times it has it seems to be warm, driven awhile. It has happened once middle of the day with no accessories running except stereo, once at night with just headlights then the other times with full electrical load. All started that one night with the surges and the battery replaced.
Any Suggestions of what may be causing my issue?

Thanks in advance and sorry for the long post.

 

Start checking all your grounds. Starting at the battery. Verify they are all good. Then go after the supply side. Make sure all the connectors are clean, and tight, including on the alternator. I begin to wonder if you aren't seeing the beginning symptoms of Voltage Regulator, or Alternator failure.

 

That's what I thought during my hunting trip. Would a faulty voltage regulator cause the truck to randomly stall and reset? Last night I started thinking something might be signaling the ASD relay but not sure what.

 

It may not be charging the battery sufficiently, and that will indeed cause the truck to exhibit some truly strange behavior.

 

Do you happen to know if there is a way to test the voltage regulator? Or maybe point me to a thread that may describe how to?

 

I would start by disconnecting all main power contacts, battery cables grounds etc and clean with a wire brush or good substitute and reassembly using dielectric grease on all contacts. For other electrical contacts and plugs I would use a good contact cleaner to get a solid conection.

 

The voltage reg is built into the pcm so you can't just replace a regulator. 14.5v at the batt with the truck running , see what the batt reads when its not running compare the two.

^^+1 to this.

Op look for the 136 amp alt that came on these truck and upgrade to that, I would also add a second batt and a top of the line batt isolator (not a cheap one). Run all your accy's off the second batt and leave the other for just the reg truck stuff.

 

I know the voltage regulator is built into the pcm. I was just wondering if there was a way to test it or check to verify if it is the problem. I will go out and clean all my contacts this week, probably Tuesday or Wednesday.

 

It is constantly being tested...... It should try and maintain 14 volts or so with the engine anywhere above idle. Yours isn't.... so, either a gauge is lying, or the VR, or Alt have an issue.

See what voltage is at the battery with the engine running. That's the first step.

 

Very belated update but last weekend I finally got around to looking at my truck while I was replacing the radiator. Found out my alternator grounding wire was loose. The nut that tightens it was barely finger tight. I did catch codes one day. Code 32 and code 34. That before I found the loose ground nothing lately and truck is running great.

Thanks again for all the replies.