CK5
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Charging system

Not much of a way the starter could cause that. Of course a lot of the wires hook up there, so thats possible.
But, you checked that.
It sounds to me like you have a mechanically induced electrical problem. In other words, everything is ok until something moves.

Most likely is a ground problem.
First method of attack, is to find a way to reliably reproduce the problem in a situation that is conducive to troubleshooting.

Crank it in the driveway, try revving it up out of gear. Give it quick shots of power. If that does not do it, try loading the drivetrain.
If its an automatic, put it in gear and hold the brakes while you give a little gas. Manual, ride the clutch while holding the brakes.

If that does not cause it to act up, get someone to watch the volts, while the engine is revved up and someone jumps up and down on the body.

From what I have read, it seems to act up when its moving or in a load. I suspect that something is coming disconnected or is shorting out when things move around. If we can find what will cause it to malfunction, we can isolate the problem.

Another test, is to attach longer wires to your meter. Set it on low volts, hook one lead to the negative terminal of the battery, and touch grounded parts of the truck.
You should have no voltage. If you see more than a half volt or so, that part is not grounded properly.

Wait, you have two batteries.
Check for a voltage difference between the two negative terminals. I suspect you may have a bad battery cable causing the voltage regulator to see the wrong voltage.

The negative cables are the most suspect, but a bad positive one could give it fits also.
 
I'll check my cables tomorrow . I know they are all secured but maybe theirs a problem with the cable itself . Thx for the info! Can't wait to get this thing fixed once and for all !
 
How have you ruled out a bad regulator? The voltage may be low at idle just because the alt can't charge very much at idle.
 
I just put a new alt in and it continued to do the same thing . Actually changed it twice . Thought the replacement was bad .
 
So, just to close this up! turns out it was the only ground i didnt take off and check . the braided strap on the back of the motor to the firewall was attached and looked fine with a visual inspection. Turns out the bolt on the firewall was in but stripped. I replaced it with a new cable to a more secure location and its been charging and running well ever since.
thank you everyone for the replies and help!
 

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