Big 3, now low voltage!

[JimHTP]

I just did the big 3 upgrade in my 04 Trailblazer. Alternator was replaced less than 3 months ago and should not be the problem. I left the factory grounds intact, and added negative terminal to Alternator case, and negative terminal to frame. I did remove the factory alternator to power wire ( just cut it and heat shrinked the remaining end) just because I was having trouble getting both of the wires to fit on the alternator post. Now I've gone from 14.4-5 to 11.5-11.9 while driving. My HU reads out exact voltage and it corresponds with the stock gauge pretty well. I used longer terminals on the battery to allow for the extra wires. The battery light stayed on the entire 30 minute ride to work and fiddling with a/c, headlights and stereo to alter the load did not seem to matter, almost like my alternator wasn't even functioning.

I grounded to the frame on a tension clip behind the bumper holding the radiator in from the side. I'll make sure I clean this tonight, but I'm really just not sure what the hell it could be. I didn't ground to the same k-member-ish location everybody seems to use because it wasn't threaded and I didnt have a tension clip long enough to fit there.

forgot to add, all of this was done with Knuconcepts 0 gauge KCA

 

[MAY03LT]

The most common cause is one or both of the wires in the alts 2 pin connector breaking off. I would check that first, followed by verifying voltage at the alt + stud (with the wire still connected to it).

 

[JimHTP]

The most common cause is one or both of the wires in the alts 2 pin connector breaking off. I would check that first, followed by verifying voltage at the alt + stud (with the wire still connected to it).

that's entirely possible, I unbolted the alt and flipped it onto its face while still connected to get at the post.

Does this mean my voltage is down or that the TB's measurement of it is off?

Whats the fix, replace the connector, alternator or both?

 

[JimHTP]

Damn i see it now. sure enough one of the wires is broken. off to a dealer to grab the pigtail for $35 ridiculous dollars.

 

[MAY03LT]

I unbolted the alt and flipped it onto its face while still connected to get at the post.

I do it the same way, it's the only way that I can get to the release tab.

For whatever reason those suckas get brittle and will break even if you're careful.

I re-read the original post and if it was at 11v for 1/2 hour the battery should be charged and tested or the alt might cook while charging it.

 

[JimHTP]

Thanks guys, that got it all fixed. Though the butt splices they supplied in no way correctly fit the tiny 22 ga factory wire.

And yes i did stick it on the trickle charger all night before starting it so I didn't cook the battery.