2010 Ram 1500, Alternator Not Charging Part 2

Part 2 of 2010 Ram 1500 alternator not charging. This truck had come in with the alternator and the battery already replaced. There were codes P063A and P2504 stored. Testing had found a large voltage drop between the battery and the alternator output post. I had traced the fault down to a damaged 8 gauge fusible link at the battery post on the underhood fuse box. There were three repair options open to me. Number one, replace the wiring harness but that would be very expensive and may take weeks to find. Probably not available either. Number 2, I could splice in a new piece of fusible link wire but 8 gauge fusible link wire is not that common either. Number three and the choice I made was to replace the damaged fusible link with a more modern alternative. So, I modified the wiring harness slightly to accommodate a 200 amp Mega Fuse and fuse holder.
I lost a good bit of footage of the actual splicing and crimping of the harness, along with how and why I mounted the fuse holder where I did.
Some of the products and tools used in this repair can be found through my Affiliate links below. Thanks, Sparky
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[@rickeyoswalt2094]

They sure don’t making them simple anymore 🤔😂

[@TrayvonGordon-by8eb]

The back of my plug in wire that goes to my alternator is reading 7volts and it won’t charge my alternator. I got my alternator tested 4x all passed. A lot of people are telling me it’s my (tipm) but I don’t have any windshield , lights or door locking issues . Do you think it could be a short in the wire ?

[@SparkysAnswers]

I would need to know the specifics about your truck: year, make, model and etc. However for a 2010 Ram the TIPM is not involved in the charging system except for the battery junction point that I wire around in this video.

[@bobbybenjamin2913]

Does this fusible link help with your alternator charging your battery?

[@SparkysAnswers]

Yes, it is the main connection between the battery positive post and the output post on the alternator. No fusible link or in line fuse holder as I installed and the alternator will not charge the battery.

[@user-xr1uj4mr3s]

Well, I'm 40 years old. For the first time in my life, I hooked my battery up backward a few weeks ago. Fairly quickly, smoke began pouring out from under the fuse box. Unhooked the battery. I turned it around. Later, it died on me. I was then I had O'Reillys test it and found out the battery was't charging. Plus, the battery light came in the dash. For probably a year or so, I could never figure out why my battery would be dead after sitting for a few days. I now have a new remanufactured alternator delivered today from RockAuto. This video got me thinking I needed to have checked the wiring. If it's the fusible link, can I put another in its place? And anything I need to check?

[@SparkysAnswers]

If it is blown, you can certainly replace the fusible link. The proper size is a little difficult to come by so I opted for installing a mega fuse and fuse holder assembly as shown in the video. The first thing to test is for battery power at the alternator battery post with the ignition off. If there is no power then it is very likely that the fusible link is blown.

[@skipper581]

You didn't show how to install the fuse.

[@SparkysAnswers]

Yes, I know I did not actually show mounting the fuse holder or installing the fuse into it. Unfortunately, I was having some issues with getting the fuse holder mounted just the way I wanted it and time was running short. All of the camera equipment was in my way and the job had to be finished for a waiting customer.