Was driving around today when I noticed that sick burnt electronics/plastic small, which can be hard to detect while driving.
Just about that time, the GEN light came on, I pulled over and popped the hood, and the alternator was literally smoking.
I was about 4 miles from home so I decided to limp home, I jacked up the heat to siphon off excess heat.
Drove fine on the way home, the smell stopped, when I got home I popped the hood again with the engine still running, and no signs at all of any trouble.

Turned it off and did a battery check with a cheapo tester, normal output.
turned it on for an alternator check and is not registering any output at all, if thats the case, I am surprised I drove so far on 0 output.
Usually, things go dim and shut down fairly quickly when the alt dies.
Also, the GEN light didn't come back on when I cranked it back up, so I don't know.
Either some guff got into the alternator, causing it to smoke, and I have a defective test instrument - Or my alternator is shot.

I'm leaning towards the last, but am going to push my luck and take my girls to the drive-in, only 2 miles away.
I just might be regretting that.

 

Canceled the drive in plan due to weather, I ended up driving about 10 miles, GEN light came on once, other than that no signs of problems.
Am coming to the conclusion that the alternator is dying a slow death.

 

the alternator is dying and you need to replace it. the smoke is from heat and melting insulation, and the heat is building up from an electrical short. its just a matter of time until something goes competely to ground and you have a complete internal burn out.

don't wait, it won't fix itself. replace it today.

 

*Fix itself*

How'd you know what I has hoping for ?

 

I'd replace it before it takes the battery like mine did when it went out.

 

Yeah I'm gonna replace it, not much of an option not to.
Drove it around a bit today, no smoke but GEN still popping on.
Tis a matter of time before I'm screwed if I keep pushing it.

Called around, was quoted 3 different amperages.
Unless there is a sticker or something on mine, I'll go with the highest amperage, since I have power everything, and some aftermarket devices which draw power.

 

Look in the power distribution center under the hood and check the rating on the alternator fuse.
I believe that will guide you to the right alt.
Some one will surely correct me if I'm wrong.

 

I thought that the stock alternator was set at like 132 amps or something like that? Would make sense because I think our main fuse from the factory is 150amps....

Now, I also want to say the the 2500's and 3500's got a 172 amp alternator, but I could be wrong on that.

 

My 96 has a 120 amp fuse, 117 amp alt..
I believe there was three ratings of alt. they had.

 

IIRC from the different build sheets I was seeing from Dodge, over the years and depending on your trim level/options, there were at least two different alternators.

Mine came with a 136A alternator and a 140A fuse. What were the ones that you were quoted?

Check that fuse, like charlie said. Stay below the fuse amperage.