2003 Expedition alternator/charging system
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2003 Expedition alternator/charging system
Purchased a 2003 Expy with 80,000 miles about 2 weeks ago. Within 3 days of having it we had to replace the fuse box. It wouldn't start and had a loud buzzing sound coming from the fuse box. Found a replacement part from the local LKQ and took care of that issue.
The truck started right up with seemingly no problems. Then the "battery" light came on. Battery tested at 11.9, low but still good, however no change when starting the truck ... ok ... alternator. Replaced alternator, no effect, light still on, low readings. Took the alternator back to Advance Auto, exchanged it for another new (refurbished) one. Same thing. This alternator is good according to their bench test. Readings of 14.5, but once installed in the vehicle all we're getting is max of 11.9.
Called the local Ford dealer, he said he recommended replacing the battery as sometimes that would affect the readings and make it seem that the alternator was bad even though it was just the battery.
New battery, same results. Battery tests at 12.6, dropped to 12.53 when cranked, stayed at 12.53, cranked again, dropped to 12.31 turned truck off battery tests at 12.44.
What's the next step?
Ford said they could test the charging system. But if the battery light happened to go off they probably wouldn't be able to tell me much.
The used lot we got it from is willing to work with us, but we're wasting time & money fixing things that don't solve anything ...
With a two year old son, our time to actually do repairs here at home is pretty limited, but I'd rather us try to test everything on our own versus paying a mechanic the labor hours. UGH.
The truck started right up with seemingly no problems. Then the "battery" light came on. Battery tested at 11.9, low but still good, however no change when starting the truck ... ok ... alternator. Replaced alternator, no effect, light still on, low readings. Took the alternator back to Advance Auto, exchanged it for another new (refurbished) one. Same thing. This alternator is good according to their bench test. Readings of 14.5, but once installed in the vehicle all we're getting is max of 11.9.
Called the local Ford dealer, he said he recommended replacing the battery as sometimes that would affect the readings and make it seem that the alternator was bad even though it was just the battery.
New battery, same results. Battery tests at 12.6, dropped to 12.53 when cranked, stayed at 12.53, cranked again, dropped to 12.31 turned truck off battery tests at 12.44.
What's the next step?
Ford said they could test the charging system. But if the battery light happened to go off they probably wouldn't be able to tell me much.
The used lot we got it from is willing to work with us, but we're wasting time & money fixing things that don't solve anything ...
With a two year old son, our time to actually do repairs here at home is pretty limited, but I'd rather us try to test everything on our own versus paying a mechanic the labor hours. UGH.
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update
Well, took it to the Ford dealer to have them take a look at it.
The mechanic seems to think the problem is in the GEM module.
Everything I've read points to the 2003 not having a GEM module, so I'm confused.
Just had them give me a ride home so they can look further into it. Would appreciate any feedback here.
The mechanic seems to think the problem is in the GEM module.
Everything I've read points to the 2003 not having a GEM module, so I'm confused.
Just had them give me a ride home so they can look further into it. Would appreciate any feedback here.
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Joined: Jun 2011
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From: southeast, PA
here is a good post on cleaning/troubleshooting the GEM module
https://www.ford-trucks.com/forums/1...l#post12731262
https://www.ford-trucks.com/forums/1...l#post12731262
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jimho
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Jan 8, 2012 11:13 AM
