I made an account here to give you guys this. I wrote up a little guide for a local group a couple years ago to help with installing an external regulator. I hope it helps.
Parts
· 1 Voltage regulator for 80's dodge
· 1 pigtail for dodge voltage regulator
· Several Feet of Blue wire 12 Gauge or heavier
· Several Feet of Green wire 12 Gauge or heavier
*Note: you can use any color or amount of wire but this follows the same convention as the voltage regulator pigtail and chassis wiring
Tools
· Side cutters
· Crimp tool
· butt connectors
· 2+ t-tap connector and spade connectors
· Shrink wrap
· lighter or small torch
· wire brush or wire wheel equiped drill/grinder
· multimeter
· 2x 1/4-20 or similar bolts, nuts, and washers
· bag of small zip ties
· Wiring diagram identifing asd relay output wire color
*optional: Soldering Iron and rosin core solder, this will prvide a better connection but is a pain in the ass for the asd relay
Installation
Disconnect posative battery terminal
Install voltage regulator on firewall such that a good electrical and mechanical connection is made with the firewall. Use a wire brush or wheel to remove paint. Do not use sand paper as it contains aluminum and will cause a poor electrical connection as the aluminum oxidizes in the future. Once the voltage regulator is securely attached to the firewall use a multi-meter to check the resistance between the negative battery terminal and voltage regulator. The measurement should be similar to the resistance between the negative terminal and most any other non isolated metal surface under the hood.
Cut wires going to voltage regulator connection on alternator and cover ends in shrink wrap heating it to cover any exposed metal and zip tie them in a secure location
Connect Green to green using wire and butt connectors or soldering iron.
Connect blue to blue using butt connectors or soldering iron.
*Note: if your wires are different colors and you mix up field and source some people will claim it does not matter, sometimes this might be true but in my experience it is not. Double check with factory wiring diagrams if in doubt.
This is the most difficult part, the color of the ASD (Auto Shut Down) relay output must be identified. for me it was blue with white but depending on the year and model it will vary. Manuals such as Hanes or Chiltons often have incorrect colors so your best bet is to get the diagram directly from a factory service manual for your specific year.
Once the color is identified open your relay box. On a TJ it should be on the passenger fender and have a diagram identifying the location of each relay. Once you have identified the location of the relay look to the opposite side of the board it is mounted to and install a t tap connector on this wire.
Using several feet of blue wire ensuring you have extra install a spade connector on one end and connect this to the t tap on your ASD output. Run this wire with the rest of your harness along the firewall and zip tie it on so it won't vibrate loosely and chafe.
Once this wire reaches your Blue wire between the two pigtails install another butt connector and a t tap on the first blue wire.
Zip tie everything to prevent wires chafing, melting, or getting pulled loose by moving parts and foreign debris which may enter engine bay.
Reinstall positive battery terminal
Start engine and check charge voltage with multi-meter, if voltage is between 13 and 15 you should be in good shape.
In my experience I usually get between 13.5 and 14.8 volts depending on battery charge level. If ~19v is present your alternator is full fielding and is likely not receiving proper signal from regulator or has a damaged diode. Most likely you got field and source wired backwards.
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