Alternator Running Hot

C

CanfieldOO7

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Jun 23, 2010
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Swapped an alternator for a 98.5-02 Dodge 2500 Cummins into a 95 Dodge 2500 Cummins. The only difference i can see on the backside of the alternator is that instead of the 2 wires that plug into the 98.5-02 the 94-98 has one that bolts on. Ive got it hooked up by splicing the wires from a Weatherpack and wrapping them around the terminals from the original harness on the truck. Its charging to ~14V just fine, however the alternator gets hot to the point that its safer to touch the exhaust manifold after a few minutes. Its a brand new 200A unit from Geno's Garage. My old unit had something rattling around inside it and it had ~200k miles on it so i wasnt thinking it was the PCM/ECM. What could be causing this excessive heat?
 
They don't normally run cold. But check it with a volt meter see what its putting out don't trust the dash gauge.
 
Tried doing the voltage regulator mod and it just made the voltage sporadic. Hooked it back up to the stock terminals and its stabilized again. Its 14.2v at the alternator and 13.8v at the batteries. I also added a 49"(its the shortest they had) 4 gauge ground to the body and it still gets boiling hot but it takes a bit longer to get to the point where you cant touch it. So its got me thinking it could have something to do with the ground but i figured a 4 gauge wire would've been big enough. Any ideas?
 
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