The alternator output wire should make a direct run from the alternator to the battery side of the shutoff switch. It does not pass through the diode. You said yours runs to a terminal block which also feeds the starter solenoid. You can't run it this way if you are using a rear mounted cutoff switch. The diode should be inline on the (excite wire) going to the alternator. I don't have the diagram here, but this wire normally comes from the alternator warning light. It will be a lighter gauge wire. The 4 AWG wire (charge/output) coming from the alternator must be a straight run, not connected to anything but the battery side of the cutoff switch.

One other thing you need to find out about is the brake lights remaining on. Could this be related to the PO installed CC?

Read through this link. It might explain better than I can without seeing it in person.

http://zhome.com/ZCMnL/tech/280Alt.html

The only thing different in this link would be way you have to isolate the alternator charge wire when you wire a cutoff switch into the system.

thanks for that link, ron. i'l check it out in a few, as soon as i post this

anyway, i'll reattach the 4AWG back to the switch. also, the alternator is GOOD, so it's definitely a wiring issue. HOPEFULLY the solution to both problems is in ONE wiring mistake. i will have to look. i took apart the covers for the column and everything APPEARED ok. how do i get the blasted ignition switch out? there's some headless screw in there......

oh, and ron, if a plane ticket from canada wasn't so expensive i'd have you down here in no time at all!

UPDATE - i figured out why it wasn't charging, etc..... the jumper i had made was to the specs on the zcarcreations page (which are for a 280 VR), and i realized it wasn't going to do much when the diode was connected to a blank connector! anyway, i found a thread on here regarding the same issue, and i made jumpers to those specs (jumper from white to yellow, diode from black/white to white/black) and installed them. no dice. car wouldn't even click the starter. SOOOOO.... that brings me back to the drawing board and troubleshooting here i come!

ok, i'm fed up with this problem. car has an appointment with Zwhizz on wednesday. while she's there i'm going to have them bleed the brake system, since my rear brakes don't have bleeders (!!)