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If it's a new alternator, return it and get another. Have it tested before you leave the store. Since the light turns off when you unplug the regulator I think the truck regulator wiring is ok. The only way to generate a lot of heat in a small amount of time is a high current short/load. Are...

I've looked at the rebuild kits on eBay. They only have two insulated screws for the regulator/brushholder assy. In an isolated ground alternator they all have to be insulated. The drivers side alternator doesn't have to be isolated ground. If the light is on, it shouldn't charge. Pull the...

No regulation is usually caused by the regulator or something in the alternator being shorted, causing the regulator to go full field. The higher the engine rpm, the higher the voltage. I've had this happen. Rebuilding the alternator solves the problem. There is a link in my signature to my...