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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

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Old 02-26-2006, 06:55 AM
digitaldemon digitaldemon is offline
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1992 F150 Charging Problems

92 F150 6cyl. Auto OD

Last May I had a new alternator and battery installed, with a 1 year warranty

August I had to take the truck back and have them fix the alt again

The other day I noticed a smell of burning insulation (elect.) the truck quit charging and the wires on the bottom plug (two heavy gauge Battery wires and one smaller gauge starter wire) had melted and almost caught the alt. on fire.
I replaced the alt. as well as the plug and wires

It still will not charge. I have tried everything I know.

The battery is at full charge but only shows about one quarter charge on the gauge

It dies when you pull the negative post off battery while running

I am getting no advance on the gauge when I rev the engine
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Old 02-26-2006, 07:41 AM
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Old 02-26-2006, 08:18 AM
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When this happens the Fusible Link "J" (14 GA-GRN) opens. On this type (2G) of Alternator you can buy a replaceable bridge with a stud on it and do away with the plug. You can also replace the Alternator with a type 3G from 1993.

This plug is a common failure on a 2G Alternator.

Fusible Link "J" (14 GA-GRN) is at the other end of two heavy gauge Battery wires at the Starter Solenoid on the Battery side.

Here is a diagram of your system.

Click the image to open in full size.

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Last edited by subford; 02-26-2006 at 08:50 AM.
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Old 01-28-2013, 02:41 PM
jross2510 jross2510 is offline
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Do you guys still have the diagram of the wiring system from the alternator to the battery? My 1992 ford f150 is doing the same thing as digitaldemon's truck.
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Old 01-28-2013, 03:19 PM
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Should have.
Email me at the email address below in this post and I will see if I can find it.
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Old 01-28-2013, 03:19 PM
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