2011 Dodge Grand Caravan Not Charging

John Manager Indiana Posted   Latest  
Resolved
Electrical
2011 Dodge Grand Caravan R/T 3.6L (G ERB Flex) 6-spd (62TE)
P0562 — System Voltage Low
Not Charging

Have a 2011 Dodge Grand Caravan RT in the shop. Got it after some previous shops had it. The van does not charge, seems as if the alternator is just inoperative. The previous shops have put in a remanufactured TIPM module. New battery. Remanufactured alternator. Used PCM programmed to the van. We have hooked a scope up to the wires directly at the PCM and the wires directly at the alternator. We have insured there is no wire issue between the computer and the alternator. This one is stumping us because it seems as if the van wants to charge, but it is just not. We're thinking about installing a brand new alternator, but they are quite expensive so we want to make sure we make the right call. We had a 2012 Dodge Grand Caravan in here and just about everything was the same on it except the generator duty cycle. On the van with the issue the generator do recycles pegged at 100% just about as soon as you start it and it never changes. The minivan that is charging has a duty cycle that ranges from 20 to 40%. 

Has anyone ran into these ghosts no charge minivans? Has seen a few other people with issues and it turned out to be pins being stretched out, another quite weird things. Any help would be greatly appreciated!

Thanks!

+2
Interesting
Lonny Diagnostician
Florida
Lonny
 

Check the battery wire where it splices off from the starter wire. Are known for shorting and frying that wire up to the splice.

0
Ð Awarded
Tyler Technician
Kansas
Tyler
 

Where is each channel connected on your meter? Guessing #1 and #2 are field control, #3 and #6 are gen sense? With the generator command at 100%, add a bulb to the field control circuit (with the other end going to B-). A stop light bulb or the like would be best. Something that takes a couple amps. Does the bulb light brightly? If yes, check for spread pins at the alternator before replacing…

0
Ð Awarded
John Manager
Indiana
John
 

Channel 1 is pin 10 at the PCM battery feed. Channel 2 is pin 29 at the PCM battery feed. Channel 3 is pin24 at the PCM alternator sense. Channel 4 is pin 19 at the PCM alternator field feed. Channel 5 is at the brown and grey wire at the alternator. Channel 6 is at the red and violet wire at the alternator.

0
Ð Awarded
Tyler Technician
Kansas
Tyler
 

Thanks, sir! The field control circuit appears to be dead. Were these readings taken with the alternator duty cycle PID showing 100%? Perform the alternator full field test as I described earlier. If the system now charges, double check the field control wire continuity and pin tension on both ends before replacing the PCM (again).

0
Ð Awarded
William Owner/Technician
Kentucky
William
 

Have you done a voltage drop test from the alternator to the battery. You should check the ground as well as the output from the alternator to the battery.

0
Ð Awarded
Timothy Owner/Technician
Wisconsin
Timothy
 

As Tyler said, apply power to the field control side of the alternator yourself, and see if it charges then. If so, then the alternator is OK, and you're right back at the PCM. TIPM has nothing to do with this, as long as the PCM is getting power to it from the TIPM…

0
Ð Awarded
Steve Diagnostician
Arkansas
Steve
 

Hello, I have ATS scope as well , mine is a 4 channel though. I have been able to catch several alternators going bad by full fielding with a scan tool, and looking at waveform with your scope at the field terminal. Could see wave form breaking down , these alternators checked out good with midtronics tester! Alt charging was intermittent, ssometimes batt. Light would come on. I would send files…

0
Ð Awarded
Glenn Owner/Technician
Texas
Glenn
 

Hi John, Is there a parts store in the area that can bench test the alternator? The alternator is being commanded but not responding. What is your PCM PID data? The new ones are expensive for a reason… quality manufacturing. A reman TIPM, where is the old TIPM? I have not heard any success stories with reman TIPM's. Used PCM… what says that is any good? The alternator is duty cycle…

0
Ð Awarded
Michael Technician
Indiana
Michael
 

Hey Glenn, We have had great success with TIPMs rebuilt by MAKs tipm re-builder. tipmrebuilders​.​com I would do this over used or dorman any day.

+1
Ð Awarded
Helpful
Thanks
Timothy Owner/Technician
Wisconsin
Timothy
 

TIPM has nothing to do with the charging system on this.

0
Ð Awarded
Caleb Diagnostician
Indiana
Caleb
 

Could you reference my response in this previous DN post? I believe it will give you the answer you are looking for. Your vehicle has the same setup as the Avenger in this post. Simply load test the B+ an grd cables to the alternator. Then scope the control circuit while commanding on/off with scanner. If everything checks out the alternator is junk. Be sure you are scoping with the alternator…

+1
Ð Awarded
Helpful
Thanks
James Diagnostician
Pennsylvania
James
 

Turn van to ON and look at the fuel gauge. If fuel is lower than a quarter tank, put 12 gls. 92 octane fuel in tank. If gauge says half-tank, turn key to OFF. Remove both cables from battery and don't allow them to touch. Reinstall original TIPM and PCM. When done, now clamp the two disconnected cables together for minimum one hour. Slow charge the battery for the hour. After 60 mins., connect…

+1
Ð Awarded
Helpful
Thanks
Kevin Technician
Manitoba
Kevin
 

These PCM’s are common for having charging issues. So much that I stock them!

0
Ð Awarded
Kerry Mobile Technician
Ohio
Kerry
 

Same here and for what it's worth about one out of four that we buy is defective for this exact problem. In addition, we frequently get calls from people that have bought a “reman” unit online from New York or Florida and they are defective for this same problem…..and they show no signs of having been opened or reman'ed! The pile of cores keeps growing….awaiting a source that can truly fix these.

0
Ð Awarded
Sean Owner/Technician
California
Sean
 

Good Morning John, every time I have seen the 100% duty cycle and it is not charging, provided every thing is intact, it happened to be the Control module, a jeep liberty comes to mind, we double and triple checked the wiring both to the alternator and ecm and because the client was jumping the vehicle, it must have damaged a driver in there, we replaced the ecm with new one since it was…

0
Ð Awarded
Richard Mobile Technician
Florida
Richard
 

This is a very good learning situation for us all on these PCM controlled charging systems. Reman's can be faulty but they are tested before being shipped to the suppliers. I usually go straight to the connector and battery post on the alternator for testing. What should be there with lights on,A/C on, radio on, etc… That vehicle has to many suspect parts with a used TIPM and PCM along with a…

0
Ð Awarded
George Owner/Technician
Alabama
George
 

You say you have 100% duty cycle…..In other words you have voltage going to the alternator rotor but no pulsing on the ground side. So ground the NEG side of the alternator rotor to check for max alternator current or use a rheostat so as you have control of output. if no current output you have a open rotor….Assuming the output alternator battery cable and ground circuit check ok…..If you have…

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

John, to begin I am the person who will drop ship an external VR if all else fails. and the vehicle must be safely driven. The external VR looks exactly the same as the external VR that was used on prehistoric Ford vehicles. It is NOT the same so don't us it. Prehistoric Ford vehicles have a field draw of probably less than three amps. The modern alternator has a seven amp field draw, which…

+4
Ð Awarded
Helpful
Thanks
Glenn Owner/Technician
Texas
Glenn
 

Hi Louis, Forgive me for not stating your name, but honestly I am terrible with recalling names. I have always had that issue and I hate it. I am glad you followed this posting and offered to help. You are the go to guy for this kind of problem.

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

Glenn, thanks for your reply. Louie

0
Ð Awarded
Glenn Owner/Technician
Texas
Glenn
 

Hi Louis, Thanks for understanding, my heart is in what I do, but sometimes my recall is a bit shaky in some areas. Recalling names is a big one for me. It is aggravating at times. Yet I can recall technical specs from 40 years ago.

+1
Ð Awarded
Funny
Kerry Mobile Technician
Ohio
Kerry
 

Louie, spot on….and I'll add 2 things. We've had three or four of these that were charging to acceptable values but the resistance measurement between the sense pin and the post was not 2.4 kohm. In every case the only symptom was a battery light, but the alternator charged just fine and the target voltage was being met when looking at data stream on the scanner. Digging into it over time we…

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

Kerry, if the resistance value of the sense is wrong then wire in an external resistor from alternator output post to sense line. Just cut the sense line and wire the resistor in. A 2.4k ½ watt resistor will be fine. This diagnosis was unacceptable. The very first thing that should have been done is determine if this is an “A” or “B” alternator. Then it should have been full fielded to find out…

0
Ð Awarded
Ray Owner/Technician
Tennessee
Ray
 

Had same thing problem was no voltage from pcm and mine was replaced with used one i re replaced and program ok now

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

John, it is totally outside and beyond my comprehension why you would consider alternator replacement without full fielding the unit. It is so easy to do this. If it does charge after your initial full field test, then, if you require this, I can advise you on how to perform a full output test. But I don't consider a full output test necessary. I suspect the problem is not a bad alternator. If…

0
Ð Awarded
Ken Owner/Technician
Illinois
Ken
 

Ran into a same problem and ended up getting alternator from the dealer, due to the low voltage cycling, some the aftermarket alternators don't work.

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

John, are there any charging codes? What about a battery temperature PID? Is it out of whack? Thank you, Louis …

0
Ð Awarded
Louis Owner/Technician
New York
Louis
 

John, hello. As I recently spoke to your technician, and this alternator puts out when it is full fielded, I have to question/wonder how, or where this measurement was made, that indicated 100% field duty cycle. This 100% field duty cycle measurement could NOT possibly be accurate, because if it was not only would it be charging, but system voltage would quickly reach an UNACCEPTABLY high…

0
Ð Awarded
Sean Owner/Technician
California
Sean
 

and the fix was??????

0
Ð Awarded
John Manager
Indiana
John Resolution
 

Thank you to everyone for all the help and ideas. I would really like to thank Louis Bernstein for going the extra mile and finding our shop on the internet and calling us up to trying to help and guide us as best as possible. It truly means a lot! Also sorry the fix update too awhile, just wanted to make sure we had the fix for sure. It turned out the PCM was bad. After full fielding the…

+1
Resolution Ð Awarded
Helpful
Thanks
Kevin Technician
Manitoba
Kevin
 

Hence why I said I stock these PCM!

-1
Ð Awarded
Unprofessional