We finally got around to jumping over the fusible link from the alternator, and that made the message go away. It seems that the alt couldn't get back to the battery through it (even though it has continuity) and that was causing the alternator's VR to quickly burn out. THANK YOU for all the help!
Yes, we did replace the belt and checked the pulleys. I also didn't mention that the alternator was dead when we first had it checked. One brush was totally gone. So when the charging system warning came on the first time, it was legit.
Thank you for the replies! The shop did replace the voltage regulator.
I will try doing voltage drop tests.
What about the engine surging at idle when the message comes on? Is that a normal thing when it detects low voltage from the charging system?
Thanks again!
2004 4.6L, 205k miles. At about 6 hours into a 10 hour drive, the Check Charging System message appeared, and stayed on. This was the first time that has ever happened. After another hour or two, the battery gauge dropped, and then the gauges went out, then headlights dimmed and finally went...
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