voltage regulator issues '91 Ram 250

[yeoman]

Hey yall, Thanks for checking out my post. I'm new to this but think it will serve me well. I bought a '91 5.9L turbo ram 250 about a year ago and I love it. Manual transmission 4 wheel drive, non-intercooled. The one issue that I have is with the alternator/voltage regulator. The regulator keeps shorting out or something causing the alternator to overcharge battery. So I drive it around unplugged, plugging in when battery gets low. Has anyone else run into this? Is there an alternator with a built in regulator that will fit this model engine? I am decent at fixing things when its obvious but I can't troubleshoot something like this. I've been told to just keep swapping out regulator when it goes, or that I can swap the the alternator with one from a chevy( add a bracket, same belt width, built in reg). and maybe one or two other things. I'm in rural northern CA with not many mechanics to ask. The guy I bought it from is the one who told me to keep swapping the reg, he's an hour and a half away. Thanks, all comments/ advice appreciated!

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[Clutch]

You could have several different things wrong.
-are you using high quality replacement parts? OEM is best.
-is the plug worn out? It should fit tightly. You can get a replacement.
-be sure the case is grounded. You could add a ground strap with locking star washers.
-I’ve seen a reference to faulty PCM and or connections.
There are conversion kits available or you could simply swap to a newer alternator. Hope this helps. Please post your solution when found.

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[watersupply189]

Hey yall, Thanks for checking out my post. I'm new to this but think it will serve me well. I bought a '91 5.9L turbo ram 250 about a year ago and I love it. Manual transmission 4 wheel drive, non-intercooled. The one issue that I have is with the alternator/voltage regulator. The regulator keeps shorting out or something causing the alternator to overcharge battery. So I drive it around unplugged, plugging in when battery gets low. Has anyone else run into this? Is there an alternator with a built in regulator that will fit this model engine? I am decent at fixing things when its obvious but I can't troubleshoot something like this. I've been told to just keep swapping out regulator when it goes, or that I can swap the the alternator with one from a chevy( add a bracket, same belt width, built in reg). and maybe one or two other things. I'm in rural northern CA with not many mechanics to ask. The guy I bought it from is the one who told me to keep swapping the reg, he's an hour and a half away. Thanks, all comments/ advice appreciated!

Welcome friend!!


2016 Ram Laramie 3500, G56, 6.7, MM3 by Double R Diesel, Rough Country Leveling, 35x12.50 Nitto G2, HID headlights and fogs plus many many other add ons.....

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[yeoman]

thanks for that! My ideal would be to switch to an alternator with built in reg to avoid any extra wiring. I wasn't sure that was possible. Could you give any more advice as to how to make that happen? Is there any modifications needed for it to fit etc. or is one of those conversion kits a better way to go? thank you

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[cumminsbadgirl]

Hello and welcome @yeoman
Enjoy our forum!



"Cumminsbadgirl"
2014 Laramie MC 3500 ( Aisin ) 4X4
MM3 Tuned by Double R Diesel

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[Clutch]

thanks for that! My ideal would be to switch to an alternator with built in reg to avoid any extra wiring. I wasn't sure that was possible. Could you give any more advice as to how to make that happen? Is there any modifications needed for it to fit etc. or is one of those conversion kits a better way to go? thank you

You can google “1991 Dodge Ram internal regulator” or 1991 Dodge Ram 1 wire alternator “ to come up with some solutions.


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[Cumminsforlife!]

Welcome


Sent from my la-z-boy

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[mdog892001]

I used a PAperformance 1 wire. Many say a Chevy 1wire will work I forget the year range you need to find


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[AnOldBiker]

@yeoman

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[yeoman]

You've been a lot of help, thanks for all your advice. Found a company that is making custom one wire alternators that are a match for first gen cummins. they are out of oregon. part should be here next week. I'll let you know how it goes.

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