I have a 94 Dodge 3500 5.9L 4 speed. I went to warm it up and in a few mins I smelled plastic burning... Shut it off and opened the hood, the wire coming from the alternator at the main fuse box under the hood was so hot it was melting the plastic on the fuse box where the alternator fuse is... Thinking it was the alternator I took it to the auto parts and it was good... They thought it may be a computer problem since the voltage regulator is not on the alternator but the computer regulates it... Strange thing is it did not blow the fuse for the alternator... Any ideas? Mechanic can't get to it for a week....<br><br>Thanks<br>Ron

 

you mite have a short check it out before you have a fire

 

The computer on the early trucks are pretty tough.Check the crank shaft position sensor on the front of the motor follow the black wire from the plug on the front of the block. You might need to clean the plug and check the air gap and adjust the sensor, You will need a brass feeler gauge to adjust the sensor<br>The adjustment and the the sensor along with the wires back through the harness are critical for the charging system. Check the continuity thoroughly.

 

what is the correct gap setting of the CPS-thanks!

 

.049 - .051" Use a brass feeler gauge (or a matchbook cover if you're desperate). Make sure you're well clear of the notches in the damper, there's a little taper near them.

 

I have a different opinion on this one. I think you have some problems with the contacts at the fuse. My reasons... If the alternator was putting out too much, the fuse would blow, no heat, that is what it is there for. The nuts on the fuse must have loosened up or the connecter on the wire that goes under the nuts. I would look closely at the whole setup around the fuse. Bet something is wrong there.

 

Hey Bill, did you see the date on the original post? Zane dragged this one up from the dungeon and hijacked it.

 

Well maybe he's still trying to figer it out...

 

Some problems just never seem to go away.

 

A credit card works for me. Good place to get some use out of the junk ones that come in the mail all the time.