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Hi Everyone, I'm just following up as I'm still struggling with this problem. I rebuilt the alternator again with all new parts. When i turn the key to run I get a Gen 2 light, when I fire the truck up the light stays on. I got fed up with it and ordered a new alternator from Rare Electrical...

that makes a heck of a lot of sense. Thanks!

no - when i rev the engine the gen2 light does not go out. I'll see if i can grab a regulator/diode trio from napa and swap it in today.

haha yea, what a learning experience. so its all rebuilt with the insulators. No arcing or shorting out. I replaced all of the fusible links. Everything starts and runs fine, but the gen 2 light stays on. I checked the alternator Key off - exciter = 0v, Red wire on plug = 25v, red wire on...

thanks warthog - I'm going to check them all out today.

Thanks makers - everything inside looks in tact. The smoke didnt come from the alternator, it came from the fusible link and bus bar. i took it all back apart, and insulated that screw. batterys hooked up fine. truck started up fine with no smoke anywhere, but the GEN 2 light stays on. I...

I noticed the voltmeter in my M1009 moving around a little bit lately when I give it throttle. the front battery tested 14.7 when running and the back battery tested 14.7 while running. However, when I gave them both throttle the rear battery would jump up to 15 -16. I had a rebuild kit handy...