I'm losing volts somewhere; it seems to get worse under a load. But it still seems low even at idle. I disconnected (from the battery) all the extras to rule out a short in those lines.

The alternator and battery (tested both) are both good. I was thinking the belt was slipping, but it seems fine. I noticed the tensioner pulley was moving at idle back and forth. So the question is under a load could it get worse and slip, then in turn my alternator isn't spinning properly, thus not charging the system? Or does that pulley move anyway and it’s no big deal?
I don’t hear any bearing not allowing something to spin, but the ac does seem a bit loud.

 

How many volts is your alt putting out when idling? Mine puts out around 14.-14.2v

 

14 even

 

13.5 to 15 volts would be normal...what is the issue you are having to make you believe you're loosing current? Rev the engine to 2000 or more RPM's and see what it's putting out for Volts...The amperage is what you would really want to check, but you would need an amp clamp for that.

 

That's not low...

 

+1

 

No amp meter, but the gauage is drops at higher rpms with a load, and it's where it normaly was a few days ago.I know its not a short it no fuses are blowing.

 

Did you check it at 2000+ RPM's? And what are the readings.

 

If the voltage is dropping at higher RPMs, you need brushes in your alternator. When they wear, and become shorter, the spring tension drops, and contact can't be maintained at the higher RPMs.

 

Pull it get it tested.

 

All ready did that. 95% sure the guage is or has gone bad.

 

I wouldn't be worried, just pick up an aftermarket volt gauge or get a scangauge II

 

On the alt there is a tiny little wire on a single connector that is not weatherproofed. It can cause the wire to fail at it or up from it. Bend this wire, if it feels brittle replace it.

Dont trust the dash gauge try and wire up something else.