Flickering lights in dash/flickering headlights.
Some GM trucks exhibit noticeable flickering dash lights and/or headlights, especially at idle with a heavy load (such as the A/C). For some reason GM chose not to use the external sense source terminal on the alternator to detect modulation in the charging current. The following fix will, in most cases, eliminate the flicker and reduce the charging voltage by about 1/2 volt. GM published this fix in a TSB, PI02010, dated June 29, 2004. I have personally tested this fix on my '02 Silverado 5.3L, but if in doubt as to applicability, please refer to the original GM TSB.
You will need to order one connector, 15306009. I ordered mine from GMPartsDirect (
http://www.gmpartsdirect.com). Cost of the connector plus shipping came to about $20.
Disconnect battery!
1. Pop off the plastic piece on the new connector. Remove *all* terminals but terminal D by inserting the end of a small paper clip into the tiny square hole on the alternator side of the plug, and pulling *gently* on the other end. (Don't poke it into the terminal itself; the small square opening is just above the terminal.) If you screw up the terminal, don't despair: You only need one, so you have three more to work with.
2. Crimp or solder a ring terminal on the terminal D pigtail on the new plug.
3. Remove the plastic shield and terminals B & C from the stock connector using the same method. Make sure you note the terminal letter for each wire!
4. Plug terminals B & C into the new connector.
3. Attach the ring terminal onto the battery terminal at the back of the alternator. I believe this one is "live" even with the ignition off, so if you don't disconnect the negative battery cable, be very careful you don't short your wrench to ground.
4. Plug in the new connector, reconnect battery and start the truck.