The system is putting out anywhere from 14.4 to 15.5 volts at 1000 RPM. The problem that it is charging erratically, and the headlights and dash lights are flickering really annoyingly.

When I turn on all the accessories, High beams, A/C, fans, etc., the power output stabilizes at around 13.6 Volts and no more flickering lights.

I checked the regulator and it is showing 7.4 volts across it. The book said this was ok.

Any ideas? I have a new battery, new terminals, and cleaned (2) of the main engine grounds. I am sure there are more I have not found them yet.

Help!

 

Check the alternator belt tension.

Check the contact on the alternator post, sometime a little corrosion can play tricks. remove clean and reinstall.

How much voltage at 3000 rpm? without headlights?

 

@letank...I ended up taking the alternator off and running it to Advance Auto to test it. When I was taking off the main power terminal it was loose where a little locknut tightens it to the alternator body. I tightened it.

BTW it tested perfect at AA. I will reinstall it and see what it does at 3000 RPM. i think you may be on to something with the terminal (post)

 

Still no luck. Lights still flickering. Anyone have any idea where the grounds are located on this vintage? Other than the engine grounds, as they easy to get at.

The alternator was putting out 14.8 v at 3000 rpm.

 

The headlight ground for my model is next to the driver side headlight in the engine bay next to the radiator, I sprayed some contact cleaner... but if there is some rust, filling to clean metal is a good way to get good contact. I got slightly brighter headlights.

Of course you have some flickering dash lights as well, so it may be something else.

Are the dash light flickering as well when you have your headlights turned off? Trying to see if it is related to the headlights or not.

 

The dash lights (brake light, seatbelt light) also flicker even with the headlights off.

I also noticed that the battery warning light is glowing very faintly. You can barely see it at night with all the lights off.

The regulators are pretty cheap on Rockauto.com. I hate to throw parts at this problem, but wtf?

 

Is your belt tight enough? It passed the test! The glowing battery light is a good indicator, it works for low or higher voltage than specs.

Otherwise, it could be as simple as a set of brushes, remove the alt back and swap brushes, they should be 0.41inch and at least 0.22inch or 10.5 and 5.5mm if you need metric.

 

Ok, I will dissect the alternator and check this out. Thanks for the help!