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Have the batteries load tested by the auto parts place. Just because they show a full charge doesn't mean they can handle the load.

If the bulb doesn't work, the alt won't charge. I'd start by replacing the bulb.

The battery disconnect is on the negative terminal of the front battery only? That would still leave the rear battery in the circuit, and I seem to recall reading posts here on SS where that can lead to bad things. Usually this comes up when someone is trying to stop a runaway starter, and they...

What voltage did you see? And you tested the two glow plugs at 24v? The glow plugs run on 12v, not 24v. That is the reason for the resistor, to form a voltage divider network with the glow plugs to provide them with 12v.

I'm not sure on the GPR109. This is from the CUCV Wiki: "GP Relay is NAPA# ST85, Advance Auto #S603 (AA is much cheaper)"

Without a meter, it is hard to say, given that you said the volt meter in the truck is suspect. If it is reading correctly, then yes, it looks to be an over-charging condition. Without a way to test the output of the alts, you might want to pull them and have them tested. Just because one is...

Is the new GP relay an isolated-ground unit? Meaning that there is no conductivity between the mounting tabs and either small terminal? The GP relay is activated by the GP card grounding the blue wire. The other one is hot at all times when the key is on. So, if the GP relay is not an...

Can you post a picture of the GP relay wiring? The description is a bit confusing to me.

Agreed. Look for the Harbor Freight coupons, they often have a cheap DVM for free with any purchase. You'll need to get voltage measurements to be determine what is going on.

Please re-read Warthogs post above yours. The orange wire is hot at all times and goes to the gauge, not the light. The black (not the white/gray) wire is the ground wire for the gauge, and is switched via the relay. The stock gauge is isolated from the rest of the dash, so does not get its...

Ok, didn't know it had a turbo... doubt the IP would make it run hot, but the heat could affect the IP. Could try pouring cool water over the IP and see if it runs, but it sounded like it had time to cool off before you tried to start it again.

I'd suggest replacing the short section of return line on the IP with a clear one so you can see if you are getting air in the lines or even enough fuel. If no fuel, the filter might be clogged, even if it is newish. If air, have to trace down the leak. Might also want to pull the cover off the...

Sometimes a bad/dirty/clogged CDR valve can cause excess pressure in the crankcase resulting in oil leaking past the rear main seal. The CDR valve can usually be cleaned and reused.

You'll need to verify how it is wired first. The DH relay mod is an attempt to address the issue of the, shall we say, less robust relay from the factory. So, if your push button is still using the relay, then it could still suffer from the stuck relay issue. If it bypasses the relay, then there...

I'd start with a good cleaning of the cluster, circuit board, housing. Some members have repainted the back part to be more reflective, with either white or silver paint. LED bulbs can be used for all lights with the exception of the GEN1 and GEN2 bulbs. It is also possible that the rheostat in...

http://www.jatonkam35s.com/cucvwinterfront.htm

There is a diode under the tape on the back of the horn relay. It is probably shorted. It can be removed, and does not need to be replaced.

By this are you saying that the switch is in the "service lights on" position?

Are you sure it is an isolated ground alternator? Test it with an ohm meter between the ground stud and the case.

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