> So . . . please help.
> What's the deal?
> Voltage regulator?
> Alternator?
Scott :
Could be either one, but most likely it's the regulator (which is inside the
alternator). Could also be one of the internal wires is rubbing against
something and shorting to ground.
The regulator is transistorized, and dissipates more heat when not calling
for full charging. From your and Paul's descriptions, it sounds like the
replacement regulators cannot take the heat, and eventually fail when
they're hot.
> I don't want to melt down my wiring harness.
The first thing to go will be the battery. After that, you'll most likely
notice all the extra corrosion from the sulfuric acid fumes the overcharged
battery has sprayed all over your engine compartment. The wiring harness
itself should be able to stand whatever the stock alternator can dish out,
but as the battery gets worse, the voltage will get high enough to start
burning out other devices.
Wiping down the immediate area around the battery, especially the clamps and
cables, with a damp rag and some baking soda is probably a good idea at this
point. Make sure the baking soda doesn't get inside the battery, but it
won't harm anything else. If it bubbles and foams, you've just found a spot
of battery acid. Even if it doesn't visibly foam, it will be neutralizing
smaller amounts. After the charging problem is solved, you might also want
to take the battery out, and wash underneath it. If you do find corrosion,
add a little baking soda while you wire brush it off, then treat with your
favorite rust preventative and repaint.
> This is my transportation back and forth to work . . minimizing
> down time is
> important to me.
One possible short-term workaround is to disconnect the alternator (engine
off) after the battery comes up to voltage in the morning, and drive without
it. In warm weather, you should be able to drive all day (no headlights),
including half a dozen or so starts, and still have enough left in the
battery to start the next morning. Although this isn't particularly good
for the battery, it's not nearly as hard on it as overcharging. This may
not work (the car may not start again), but if so the battery was almost
dead anyway.
Randall
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