1973 Dodge Charger Rallye - Over-Charging / 4-pin Ballast issue? Wiring issues!!!
Wiring issues here!! Restoring a 73 Charger Rallye (came w electric ignition, 4 prong
ballast on firewall). Car had some major shorts at bulkhead, but is now starting and
running after removing the "Amp Meter" circuit & connecting the alternator output
directly to the starter relay. Ran new volt meter under dash instead. At same time,
bypassed the main hot lead through bulkhead with an independent 8ga wire through it's
own new firewall grommet. Had to fix a few melted wires that these two wires came in
contact with under dash & shorts now seem to be resolved... I couldn't find any 10ga
fusible links, so running a 40A fuse on the main hot wire from battery to firewall, and
currently am NOT running any fusible link/fuses, etc. between alternator & starter
relay... now that you know the history, here's what it's doing:
Voltage at battery kept climbing and I would finally have to shut car off when it spiked
over 17v.. It was popping these 40A fuses constantly and also blew a few voltage
regulators. Prior to me working on it, it had previously blown a coil and also the ignition
control module. Now that we've resolved the shorts (best I can tell), I'm pretty sure that
the 4prong ballast was flip-flopped. Apparantly it's been wired like this for over 20 years!
It was getting full power to the leads going into ballast, and the brown wire going to coil
was ALSO getting close to full voltage (about 12.6 when battery was reading around
12.8-12.9). The (+) lead going from ballast to the alternator WAS NOT getting full power
(was reading about 11.4v). I read enough to find that the coil should have the reduced
voltage, and the alternator should be getting the bat voltage, so I flipped the resistor
around and now the alternator (+) is getting the 12.6(ish) to its lead, and the tan wire
post to coil is now getting the 11.4v... So far after flip-flopping the ballast (and replacing
ANOTHER) voltage regulator, the car is running and not blowing the 40A fuse anymore,
but when I hook my volt-meter to the battery, it shows to be charging at around 16
VOLTS at high idle! The voltage regulator is keeping it from going much above 16v, but
that seems REALLY high. Wierd thing is that the new volt-meter under dash is showing
barely over 14v. Is there something that I'm missing here? I'm not totally sure that
flipping this ballast is correct or not, but according to what I've read it was a good
educated guess. The plugs have prongs that only allow them to plug in in 1 direction,
so there shouldn't be too many variations until I can get this thing right! The side with
the notch in it currently has the wire that loops from top to bottom on the 2 prongs, (left
hand side if your facing it from front of car). The right side has the tan lead on the
bottom prong that is showing 11.4v (going to coil)... Could this ballast be the issue?
Can't find correct Ohm specs for this ballast or volt specs (prong for prong - for
dummies!) anywhere to use as a guideline.. If ballast specs sound correct, why is it
charging so high? Could a fusible link on the alternator wire add extra resistance to
slightly lower the voltage? I don't figure I should have to put a "capacitor" on the
"alternator-to-starter relay" wire, so I'm pretty sure I'm missing something!... Slightly
clueless on this one so any help appreciated!
I have a couple of other issues besides this, but this charging thing has me stumped!
Dash lights don't seem to work, temp gauge & oil pressure gauge don't work! (bought
new sending units but haven't installed yet). Also, we installed a new headlight switch
throughout all of this, and everything functions as far as high/low beams, brakes,
running lights, signals, etc.. but when the headlights are off (even if ignition is off), if you
twist the switch (to brighten/dim the interior lights), instead of fading the interior lights,
it greadually turns the running lamps on!!! There was one stray purple wire that wasn't
in the connector, and I thought I put it on the same post it came off of when re-
installing, but it's very possible that I may have connected that wire on an incorrect
prong or that it came out of the original connector.. not sure.. still have to check that
out after I fix charging problem!