11Feb21 102,97? mi
Driving home from work the dashboard lit up like a Christmas tree. I had CEL, Parking Brake, Seatbelt, Traction control, & Multi-Terrain all came on solid with flashing 4WD and Crawl Control. Obviously these are not all connected to the same ECU so the issue was more complicated than just a bad sensor. After a few restarts I just drove it the 7 miles back to the house and parked it.
12Feb - I checked under the hood looking for obvious issues or blow fuses and immediately noticed the X2Power AGM battery leaking. Well that's not good, so I pulled and replaced it with a flooded type. Truck started, but still had all the lights on the dash. I had to get to work so drove the car instead.
13Feb - Get off morning shift and drive truck to O'Reilly's. They check the alternator, confirm it's bad. It's putting out 19V!!!! They read the codes, and they're all over the place, but mostly voltage issue related, and primarily to the ABS/speed sensors. Drive truck home and devise plan. I still have the OEM alternator somewhere in the garage, and it tested good, so I'll throw that in. Make a deal with my buddy for his help, standard beer & pizza, with promise to get truck in the garage and warm it up some.
15Feb - Try to start truck, battery dead. Try to use car to jump truck, not enough juice. Use car and jumper cables to charge up the battery some, enough for it to take the jump charge feature on the smart wall charger. Try to start truck, starts, then immediately dies. Repeated attempts to restart, the engine turns but won't catch. Still have the bad alternator in at this point, so I figure I overvolted something and killed it. Remove new battery I just killed. Tempted to arrange tow to dealership, but buddy is insistent with his help we can start it.
16Feb - Buddy & I remove 270A bad alternator, and install OEM alternator in 20F before the windchill. Involved several trips to hardware store for bolts as the 270A mounted slightly differently. He brought a fresh battery too. Engine turns but won't start. He tests lots of fuses under hood and dash, and we come up blank. It's obviously a no-spark or no-fuel issue, though we can't figure which or what's causing it. Still has all the dashboard lights, but is now throwing codes for ignition coils too. Arrange tow to dealer for next day.
17Feb - Truck was towed to dealer. I swapped the bad battery for a new one. When I turned in the bad battery they noticed it was now leaking through overflow port where it wasn't previously. But they swapped it out still (Thanks Batteries+Bulbs!). Took good battery to dealer, give service rep the story.
18Feb - Dealer calls. The installed the new battery and finished cleaning up the alternator install (we only connected it enough to work, not mount all the cables cleanly). They spent a couple hours troubleshooting a no-spark issue which turned out to be the fuel injector fuse. That's it, a blown fuse was all that my buddy and I had missed.
20Feb - Got a buddy to give me a ride to dealer after work for pick up. Service guy was thrilled about my ATREIDZ license plate and Muad'Dib hitch cover, though missed on the Klingon front license plate. I hated to pay them a few hundred to change a damn fuse, but diagnostic time and all.... at least I had a general labor & parts coupon that saved a few bucks.
I emailed DC Power about the alternator issue and asked about a rebuild. They're happy to rebuild it for me, and it should cost about 1/3 the cost of a new one. Given that's still less than cost of a new aftermarket OEM spec one, I'm going to do it. I probably just won't mess with putting it in until the OEM one dies (if it does).
Thoughts and musings given this saga:
1) Anything below 45F is too cold, especially for holding metal tools and removing metal parts. Swearing and tool fitment issues increase the lower the temperature goes.
2) I should have parked the 4Runner in the garage when I had the chance after having the alternator tested. Never assume because something started once that it will do so again until you've remedied the issue.
3) I caused this. Seriously, it took some thought and figuring, but it was me. 2 years ago when I put in the AGM battery I remember reading many threads about the required higher charging voltage for the AGM batteries and I added the
GM diode to the under hood fuse block. Except I didn't need to do this with the DC Power 270A alternator as it already uses 14v instead of lower OEM voltages. I removed the GM Diode before I had the alternator tested and put the factory 7.5A fuse back in. Not sure I'll bother with the GM Diode even with the stock alternator now that I'm back to flooded type.
EDIT: Apr21. DC Power & Engineering were able to repair the alternator for a minimal cost compared to a new one, OEM or aftermarket. It's been reinstalled in the truck and the GM Diode removed.