Alternator hell
 

The basics:
2005 Dodge Magnum SXT AWD, 3.5v6. All that aside, having the Devils work on this alternator. Replaced it back in march, it just died. Now the new one just capped out. New one benched perfect so I know it's not that. Runs for about 10 minutes then throws the alternator light and runs real funny. All grounds are good, new battery. So am I missing something small here or is this a common issue?

Replaced it back in march, it just died. Now the new one just capped out. New one benched perfect so I know it's not that.
Is this all referring to the same alternator, or two replacements?


Is the alternator charging the battery?
What is the voltage on the battery with and without the engine running?
Clean where the alternator cable attaches to the IPM.
Also clean the battery cable connection to the IPM.
Make sure you have good ground from the battery to the engine. There should be a cable from the battery negative to the engine.
Not sure about yours, but the battery connects to one side of a 140 amp fuse, and the alternator connects to the other side.
Just for fun, use your voltmeter to check for any voltage across that fuse.
It should be zero.


The voltage regulator for the alternator is in the PCM, by the way.

You won't believe this
 

Ok, so the original one that died and I replaced fixed it the first time. Then this one died and I replaced it, cool. But here comes my luck. Somewhere between changing the sparkplugs and putting this new alternator on, the egr done.... something, and pissed the new alternator off causing the light. So the new alternator is fine but it was the freaking egr. So, my luck, an egr can throw an alternator light. :-/

Check the terminals in the field coil connector on the back of the alternator.




The EGR has nothing to do with the charging system.

I realize that. But as I said, it was my luck something like this happened. Nearest I can figure, a brush or something flew out of the alternator and took out the egr. The new alternator that's on there is completely fine. It's just my luck something like this happens. But I has been resolved :-)