I've read through most all of the alternator threads on here and I'm still stumped. The charge/brake light is coming on but sometimes it stays off until I start driving. I pulled the alternator and had it tested and its charging at 14 volts, battery testing as fine, 80a FL is good, 7.5a charge fuse fine, engine fuse fine, sanded and cleaned up all the wire connections associated with it, and still its testing as the alternator not putting anything out. I've run out of ideas. The belt is tight and the connections are solid too. Yes I'm sure that its not charging too since its running on battery power and died off on me the other day. Its an 89 toyota 4runner 22re 5spd dlx. Any ideas?

 

there are electronics gurus on here that know way more than i do, but isnt there an electrical 'leak down' test? like, hook it up to the battery and it shows you where the lost current is going? or am i just wishful thinking? and your connections under the dash all work fine? and the fan isnt loose, pulley is good, etc?

 

I'm not too sure about the leak down test, I've never heard of it. The belts are all good and tight. Sometimes when it sits overnight or for 8+ hours at work the light doesn't come on until I drive about 2 or 3 minutes.

 

just becuase it tested ok when they bench tested it doesnt mean its good. You said the lites go off and on right? That tells me your brushes are down enough so that they make enough contact to chrage here and there but will lose connection. I would replace my brushes and see how that goes. Brushes are $20 shipped to you BTW. lol

 

I was figuring the problem could be with it warming up and parts expanding causing something to lose contact. I don't have any time to myself for the next few days so rebuilding isn't really an option. Im just going to get a pep boys lifetime replacement alt. God I can't believe I just said that I'm going to buy an electrical part from pep boys.

 

X2, I'd rather have my stock alternator with new brushes than some unknown alt that was refurbished by some unknown person with the cheapest and fewest parts they could get by with. A warranty doesn't do you any good out in the middle of no where.

 

Replacing your brushes will take you an extra 15 minutes aside from the r&r of your alt. Stick with your stocker. You will spend more time pulling your pep boys alt out replacing it. Save yourself time and money by doing your brushes