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2006 dodge 2500 6speed 4x4. Alternator suddenly quits charging. Had the batteries and alternator tested. Batteries where good but alternator failed. Replaced the alternator and it’s still not charging. Replaced all 4 terminals and cleaned everything. I keep reading about these “fuseable links” but can’t seem to find any great info. I tossed the alternator power wire like an idiot. Because I thought it was just a normal wire. So temporarily I used 3 strands of 12g fuseable link wire to replace it. At the same time as replacing the fuseable link I tied in a 16g ground wire from the alternator plug to a ground on the inner fender and bam the alternator is charging. I firmly believe it’s the ground I added that did the trick. So my question is... does that mean the ground going from the alternator to the ECM is broken somewhere between? Where can I find the “fuseable link” wire, because I can only seem to find 12g and smaller from parts stores. Also, would this cause a rough idle? Like my signature says, I’m on a fresh rebuild make 1,500 miles on it. I put bosh reman injectors in and had the cp3 tested at the same time from a local shop. The truck fires up without hesitation and runs solid for about 3 seconds and then the fuel pressure dips so low the truck will stumble and die out. If you give it a little throttle it will stay running and eventually the fuel pressure stabilizes and it will clear up. I’ve also noticed Some fuel residue on the high pressure line/fitting coming out of the cp3 and some fuel residue at the base of the fuel pressure relief on the rail. I’m assuming that’s my issue and it’s letting air in the system? I put a new fpr on the rail a few months back and it never had any issue. I can post the idle/ fuel issue in a separate thread if needed. Thanks in advance for any info you can provide.

Today I went to borrow my friends car hauler to rescue my broken down commuter car and only the brake lights and turn signals would work on the trailer. I tried my second 7 pin connector for the 5th wheel in the box and it was the same thing, so I figured the problem is upstream of the 7pin connectors. Did a bit of reading and found the big square 40a fuse in the fuse box in the engine bay and sure enough she was toast. Stole the 40a from the fuel heater until the parts store opens in the morning and everything was working again. I'm looking for some suggestions why this could have happened? I My guess is that it was one of the following things: 1) 19 year old truck and maybe just time for it to go? 2) My 3 year old son likes playing with water guns and could have squirted a bunch of water in the 7 pin connector and shorted something. 3) I have LED reverse lights on my dump trailer and maybe I was in reverse long enough for it to cook the fuse 4) maybe somewhere there is a corroded wire that is creating a lot of resistance If the fuse pops again, where should I look first? After replacing the fuse I drove around with my friends trailer and it was fine. When I got home I hooked up to my dump trailer since I will be working tomorrow and everything worked fine with the new fuse, so I don't think there is a short somewhere since the fuse didn't pop. The only relevant information I can think of is I recently replaced the battery on the dump trailer with a larger capacity deep cycle battery, but I don't see how that would matter. I've had the LED reverse lights on the trailer since I rewired it 1.5 years ago. I don't remember the numbers on them but they aren't a high power light. Maybe if I blow a fuse again I can run a relay with the main power source coming from the dump trailer battery instead of powering straight from the trailer wiring? Any advice would be greatly appreciated! Thanks!

My Airdog 150 quit working yesterday. After checking it out I found that the pump is working fine if I jump 12 volts straight to it, which leaves me at a relay or wiring problem. Does anyone know the part number of the relay I need? Any other suggestions would also be welcomed. I really hate wiring problems!:banghead: