MattP

Thank you for all the replies. I am still chasing down this issue but will definitely update when it is resolved. wil440, you are correct, I need to find a better location to ground than the body. I will try that out. Aside from that, I have all new battery cables and connectors to put on sometime this week (the old ones are stock and in pretty poor condition). I am hoping that one of these will do the trick. I tried a different ASD relay and that didn't make any difference.

Thanks! If I am reading it correctly, it looks like the only thing that it affects is the PCM/ECM which regulates voltage to the alternator... and that's pretty much it on the 12v (on a 5 speed anyway). This confirms my initial assessment. If I install an external voltage regulator, it should remedy the issue, correct?

I ordered mine from retroshop - the link above. They were pricey, but worth every penny!

Gen light came on a few days ago so I pulled my alternator and it tested bad. I replaced it with a cheap reman and it still wasn't charging. Today I notice that the 30A engine control fuse was blown so I replaced that and started the truck. Bingo! Everything was charging as it should. I took the truck for a victory lap around the neighborhood and the fuse blew again. Popped another fuse it to see if it was a fluke and it popped too. Recently I have installed HID headlights, but don't believe those are the problem because everything worked fine for a week or so... on the same day as the headlights, I also installed a new bumper. There were a couple of ground cables connected to the old bumper bracket that I moved to a spot on the body (new bumper didn't have a good location). I figure I am dealing with a short somewhere or a bad PCM? Any thoughts? Thanks in advance!