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Crazy charging issue. I need help!

xrbeach13

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So mid November I noticed a buzzing noise through my aftermarket stereo and noticed a slight drop in voltage at the same time. I found the alternator only putting out 30 amps max. So I ordered a high output alternator from power bastards. Installed it and amps jumped up around 50 with a bunch of loads on, the buzzing noise continued so I started messing around with speakers and amplifiers and found 2 tweeters blown and a sub which must have happened right after the buzzing started. So I replaced those with new and no fix. Swapped headunits no fix. I started testing all grounds in the truck with nothing found. I replaced the alternator main wire and ground wire with 0 gauge copper wire. Performed a component test on the ignition switch had slightly higher resistance so I replaced too with no fix. Started digging through alldata at work and found the body ecu control is attached to the alternator circuit so since I've been throwing parts at it anyway I decided to order that too lol so now with new alternator battery ignition switch power and ground wire new terminals new used body ecu and ignition noise isolator the problem continues. I ohmd out all of the alternator wires without finding anything except that the alternator wire that goes the the body ecu and cluster has 12 volt with almost no amperage to light up a test light. So I played with my truck non stop for almost 3 months after work with no luck and alot of cursing. Just as want to give on it the voltage gauge starts bouncing while I'm on the highway. Now the alternator is hardly putting any amps out and is erratic. So today at work I ripped everything aftermarket out stereo air compressor cutout just to aid in diagnosing but I'm about to give up I've talked to multiple toyota shop foreman that I used to work with with no new ideas. It's a really wacked out charging issue but if anyone has any ideas it would be greatly appreciated.
 

NHXRUNNER

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Damn rich that sucks. I wish I could help you but you’ve done everything I would have suggested. So you haven’t been able to pinpoint where the actual sound is coming from? Or is it the head unit but can’t make it stop?
 

xrbeach13

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So the noise through the stereo is being caused by a charging issue I believe.But I replaced everything in the circuit except for the wires from engine fuse block to body control module( interior fuse block) and the cluster. Checked diodes and resistance in cluster but just with no specs to go by, at least one of the two diodes are good in the alternator circuit in the cluster. the suspect wire with a test light on it shows almost nothing. Very weak wire coming from both body ecu and cluster. Unplugging the body ecu and alternator the voltage remains but only goes away when unplugging the cluster. This is the only thing I found but no body has been able to tell me what kind of voltage or amperage should be on this circuit.
 

mejbro

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When you hear a buzzing you usually want to look for kilowatts. On industrial motors you can hear the frequency if the kW is over a specific limit. I dunno if that helps.
 

mejbro

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Also, are you running an Optima ( yellow top ) or similar? Sounds like you got quite the system.
 

xrbeach13

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I've been planning on trying to test the fuel pump circuit for noise but the noise remains present with the relay removed until stalling. Also I have a dual battery set up with and isolator to a northstar SMS agm220 for the stereo because I'm running about 4000 rms to 18 speakers but noise wasn't present through the stereo with the stereo battery removed. Noise never happened while the the two batteries were connected in the first year of the stereo.
 

mejbro

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Everything listed would have a fuse to protect the circuit. Fuel pumps fail with higher mileage, power adders without upgrading fuel system etc. Sadly, when my Iroc Z Camaros fuel pump whined, I hit the top of the fuel cavity with a dead blow. ( What? I was 13 and removed the back seat )
Maybe the alternator is an isolated incident that you've solved. I've had buzzing noises come from my stock exhaust, even the new exhaust from the hanger rubbing the cross brace under the tranny. Is it louder in the cab, outside the cab?
I apologize for adding to your original questions. Wish you the best of luck
 

NHXRUNNER

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Also have you tried pulling the HU to see if the buzzing stops?
 

Edgeman

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Guess try to do the simple stuff first. Have you had your battery tested by something that can put a load on it? If not, then head to your local Advance Auto or Auto Zone to have a free check. How did you test the alternator output? Heck, have them check that too.

Once you know those are good, you can move to the next possible culprit...
 
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