Rodeo :: 1997 2WD - Dash Warning Lights Lit Up And Electrical System Not Charging


Jun 16, 2014

1997 3.2 2WD 299,000 miles original alternator

3 times in the last month when I start up first thing in the morning dash warning lights are lit up and the electrical system is not charging. AC doesn't work and windows operate very slowly. A simple rev of the engine has resolved the problem. However, the belt is very tight (and I mean very) and there is no indication of it slipping.

This morning, a rev didn't solve the problem. I only work a few miles from home and my mechanic is also very close so I just figured to head that direction. About 1/4 mile later charging kicked in and everything worked just fine.

I hate Intermittent electrical problems Where to start.

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The belt is checkered on the inside but not frayed. It deflected about 7/16ths inch midway between two pulleys about 17" apart. The Haynes manual said 1/2 inch was maximum deflection for that span. No unusual noises from the alternator.

We ran a checklist from my Haynes manual but I think it has an error in it. Here are the two steps that don't make sense. I marked the parts that seem to contradict with asterisks.

h) Disconnect the battery cables (negative first, then positive). Inspect the battery posts and the cable clamps for corrosion. Clean them thoroughly if necessary. Reconnect the cable to the negative terminal.
i) With the key off, insert a test light between the negative battery post and the disconnected negative cable clamp.

1) If the test light does not come on, reattach the clamp and proceed to the next step.
2) If the test light comes on, there is a short in the electrical system of the vehicle. The short must be repaired before the charging system can be checked.
3) Disconnect the alternator wiring harness.

(a) If the light goes out, the alternator is bad.
(b) If the light stays on, pull each fuse until the light goes out (this will tell you which component is shorted)."

Well, we decided that the last instruction in Step h should be to reconnect the POSITIVE cable (but could be wrong). I did this and we did Step i as written. The light came ON (Step 2). Disconnect the alternator wires at two points. Light stayed ON. Pulled every fuse under the hood and on the kick panel by the clutch. Light stayed ON.

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