Truck is an '04 with the 4.0L engine. After replacing the alternator, starter doesn't engage with the key, will engage when relay contacts are shorted. Also blowing the 30 amp PCM relay fuse.

 

58 reads but no replies, so will see if I can get things started. With the PCM relay fuse blown a lot of things don't wake up & function, so you need to trouble shoot why this fuse is blowing???
Was it blowing Before the alternator replacement & if not When now in the start cycle is it blowing???.
Did you have the replacement alternator Bench tested before leaving the store with it??? Its usually a good idea for us to bench test All electricals before leaving the store because new / reman / rebuilt / salvaged, doesn't automatically make em good!!!
If it doesn't blow @ KOEO, before cranking the engine, use, borrow, or come by a ELM scan tool & running FORScan diagnostic freeware on the viewing device of choice, as discussed here & have it scan for trouble codes. Low Cost ELM Scantool - Ford Truck Enthusiasts Forums (ford-trucks.com), as this inexpensive but powerful combo can query All of the vehicle computer / controllers for trouble code clues, including set, pending & Ford enhanced codes, then post All code Numbers as they can help focus a trouble shoot.

Some beginning thoughts for consideration, let us know what you find.

 

Well Lanny, how is your electrical trouble shoot going, 114 curious minds would like to know what you've found???

 

Had to put a second alternator on it, seems to be doing fine now. Thanks for your help

 

Ok, good feedback & to hear all now seems well after the second replacement alternator installation.

 

Any forum feedback trouble shooting findings info to post, as it could help someone searching for guidance on their like problem???