I have a 1980 Volare with 16,000 miles on it. Twice I have noticed a problem with the epoxy(?) filler on electrical items under the hood. The first was the voltage regulator which began to have this material leak out from behind it about a month after I got the car with 8500 miles on it in 2007. I replaced it and no more problem. Then the Ignition modual on the fender began to do the same thing at about 14,000 miles. Replaced it and no more problem. However this year I have noticed the voltage regulator that I installed (NAPA) is leaking again. Does anyone have any idea why this is happening again? Battery seems to charge properly. Guage is about half way over on charge side at start and then shortly goes to small rate of charge. Battery is a little weak(shows low good on load tester). Any help greatly appreciated. Thanks

 

This seems to be a recurring question on many forums, and I think it's the "sign of the times." That is, poor quality cost cutting and third world manufacturing.

It makes me wonder how Waltrip manages to get his race car around the track. At one time, NAPA was the quality parts store that anybody else should have strived to duplicate. Nowadays, at least some of their parts equate to the same junk as any other Big Box store.

I've had people suggest that one solution is to find sources who sell "old stock" now necessarily "new old stock" IE OEM Mopar boxes that have been salvaged

Even Mopar Performance has taken some hits from people bitching about their QC.

 

:driving:Next time you run your car for a long time touch the voltage regulator and ECU...I bet you will find that they are very hot or more than you think they should be....even though you car is low mileage the age of the wiring is 30 years old....connectors at the ECU...Voltage regulator and the bulkhead head connector start to offer some resistance...resistance = current drop which results in heat and more load on the electrical system. I would clean your connections and then use a good dielectric grease on them...my regulator I took off had some of the resin melting on the back of it...I had a 440 with a ECU mounted to the back of it that melted and got all over the tranny I decided to use...I think it was a pretty much hit and miss thing that occurs right out of the factory...another factor is adding a new stereo system with subwoofers and such..they put added electrical strain on the battery, wiring and voltage regulator...

 

Thanks for the thoughts and suggestions. Sorry to take so long to reply but I had login problems that I finally fixed.