"...dodge dealer was to alt was to small not enough volts."
Go back to that Dodge dealer and politely beat them about the head and shoulders with the old alternator. It's the voltage regulator that determines the volts.
A fuse never blows because of volts, be they too low or too high. They blow because the amps in the circuit that is greater than the fuse's amperage capacity and causes the metal in the fuse to heat up, melt, and break the circuit. In any case, an alternator that is outputting too few volts is hardly the likely cause of too many amps.
A 200 amp fuse could be carrying 2000 volts, or 2 volts, doesn't matter, as long as it's not trying to pass more than 200 amps through it.
amps x volts = watts
200 amps x 12 volts = 2400 watts
(watts / volts = amps, too. Look, Ma! 8th grade math!
)
So the question is, what do you have running off that fused line that is more than 2400 watts at 12 volts? If the answer is nothing (likely), then there is probably a short (or a frayed wire, as someone suggested). That's the alternator terminal to the battery's busbar, and there are other fuses off the same busbar with fewer amps. If you had something connected to one of the other fuses, one of those fuses would blow before the 200 amp fuse would.
So, unless you have something else connected directly to the same terminal bolt as the alternator, and are thus running it off the same 200 amp fuse as the alternator, the culprit almost has to be a short in the alternator's wiring harness somewhere.
Slow and steady, even in expediting, wins the race - Aesop
