Replace manifold gaskets - Barely runs now

[V8Notch]

2000 4.0 OHV Ranger, 5 speed. Ran fine but the lower manifold gasket was leaking coolant.

I replaced the lower intake manifold gasket. I got the whole Fel-Pro upper/lower set with the upgraded design. I used “The Right Stuff” to seal the front and rear manifold to block joints.

Marked all my wires and was pretty careful. Torqued using the listed sequence and settings.

I did make one mistake of hooking my battery back up to take a CD out of the stereo. Having forgotten about that I went to pull the alternator wire and sparked the wire on the alternator case.

I reassembled everything and fired it up. Extremely rough idle (600-700rpm) and it sometimes surges to 2000rpm, sometimes it stalls.

I was pretty careful with cleaning the gasket surfaces and following the required torque values so I am hoping it is not gasket related.

One thing that is different is the Battery warning light is now on. Can the low idle (600-700rpm) be causing this or did I fry something when I spark the wire on the alt. case?

I have tested the following:

All fuses look good, including the 125Amp one off the side of the fuse box. I checked that one with the Ohm meter.
0 Ohms from the alt terminal to the B+ terminal (so the wire is still good)
When running battery voltage is 11Volts. Seems low so I took the alt. to the parts store and it tested good. They did it 3 times to make sure.

Am I missing something? Is there a fusible link somewhere that I’m missing? I can’t afford to just toss money at it and I need it running ASAP.

 

[chuckabrick]

I would get the alternator tested by a shop that tests the amps while its running. Sears auto center will usually do it for free.