Morning Nick,
good idea getting all the bits together first. A few of us use a company online called AES (will sort link out). They have lots of electrical stuff.
There are lots of connections in the Mopar charging system from the factory which is fine when everything is new but after years of use, connections oxidise, wires go brittle etc and heat builds up due to high resistance in the circuit.
One of the easiest things to do is to very carefully separate the bulkhead connector and carefully clean the electrical connections inside.Then pack it with dielectric grease (MickRR put me onto Dow Corning DC4).
The path of the charge from alt to battery on the original system is very complicated and full of points that can cause issues. It goes from the alternator into the engine bay side of the bulkhead connector, out of the dash side of the connector, into the ignition switch, out and into the ammeter, out and into the underdash welded splice, back out through the bulkhead connector, through the fusible link and finally into the battery!!! Horrible and plenty of opportunities for resistance and heat to build up.
The bypass cuts this right down to just a couple of connections between the alt and battery, and replaces old wiring with good new stuff.
Im a novice at this Rich and have to keep notes on everything as I forget stuff quicker than I learn it, There are tons of diagrams in the various threads on here that are very useful and explain the theory behind whats going on and definately worth trawling through.
cheers Steve
