Kd4jfd is right on. Second runner up is wsauer with improper grounding. The answer is Loose and dirty connections. Improper grounding falls into that category. Brad
I was told that heat(from work overload) was the killer of alternators due to weak batteries. Rebuilders have also told me a high number of alternators are condemed and still in working order. On the subject of alternators. Delco has just come out with a simple tool to check alternators called Intelli Check. It has 4 led lights. Hook up one lead to alt. pos. term. and one lead to alt. neg. term. or ground. Start eng.,run at high idle for ten sec.,then turn on all accesories and run at high idle again. I weeded out 2 problems waiting to happen, out of the first 25 or so I tested using my dealers meter. I ordered one for my shop at $300. You could show anyone how to do it once and they will be experts. Peace, Joe
Yes, Heat is the other main cause. Depending on who you talk to. One of my rebuilders can't decide which is most common and rated them as equal. Personally have seen failed alternators with loose connection at the hot stud but I think that heat was the cause of them coming loose. There are many reasons why they fail including bad grounds but the most common are loose connections and heat.