Is the dash charge light on? If not, then my first suspect would be a bad battery (yes, I did read that you said it was good). With the battery fully recharged, what is the static and running voltage at the battery?
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Hi everyone, just wanted to follow up, and report the conclusion.
First off, I think the initial intermittent condition was likely due to oil dripping onto the original alt, for probably years.
After replacing the alternator, it's possible I shorted the battery connection at some point, perhaps the disconnected ground cable had moved over to the post, when moving some stuff around.
But, even then I was getting battery voltage at the alternator end. I was testing some more, then noticed it wasn't getting battery voltage there. So I decided to look a bit more closely at the 150A fusible link, and it would wiggle, and cause the voltage to blink ... As I took it off the posts, it literally crumbled in my hand. Okay ... went searching, and it's not an easy find. BUT I noticed that it's pretty much exactly the same size these simple Volkswagon links, and you get a whole bunch! $5 at Advance and we're back in action!
Thanks @tad844 for the docs, I hadn't really thought to check that fuse specifically, since it 'looked' just fine, and I was getting battery voltage at the alternator. I think perhaps the design allowed it to be blown, but still wiggle and pass enough to power the multi-meter, but probably just burned away a little more any time the full amperage from the alt was applied.
You can see the new one installed just above the package.
![112998]()
Below is the crumbled remains, the 'body' was super brittle and loose, it was wiggling and that was apparently enough to make some light contact, and give me a false reading.
![112999]()
First off, I think the initial intermittent condition was likely due to oil dripping onto the original alt, for probably years.
After replacing the alternator, it's possible I shorted the battery connection at some point, perhaps the disconnected ground cable had moved over to the post, when moving some stuff around.
But, even then I was getting battery voltage at the alternator end. I was testing some more, then noticed it wasn't getting battery voltage there. So I decided to look a bit more closely at the 150A fusible link, and it would wiggle, and cause the voltage to blink ... As I took it off the posts, it literally crumbled in my hand. Okay ... went searching, and it's not an easy find. BUT I noticed that it's pretty much exactly the same size these simple Volkswagon links, and you get a whole bunch! $5 at Advance and we're back in action!
Thanks @tad844 for the docs, I hadn't really thought to check that fuse specifically, since it 'looked' just fine, and I was getting battery voltage at the alternator. I think perhaps the design allowed it to be blown, but still wiggle and pass enough to power the multi-meter, but probably just burned away a little more any time the full amperage from the alt was applied.
You can see the new one installed just above the package.
Below is the crumbled remains, the 'body' was super brittle and loose, it was wiggling and that was apparently enough to make some light contact, and give me a false reading.
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