Charging Issue 03 Expedtion
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Charging Issue 03 Expedtion
Hello everyone, I have been on here for a while searching for a way to correct this issue, so far I have:
*Replaced the terminals
* checked the ground for continuity
* Fixed the frayed wire that hits the a/c line
* bench tested the alternator
* replaced the battery with a 850 cc amp one(although i am in Florida)
* Checked the alternator cable for continuity
* checked the #9 fuse
*switched the R05 Relay with the R03 one as I didn't have another relay to replace it with.
* Charged the Battery and had it tested again for verification at the parts store.
I am thinking that maybe one of the relays that are soldered to the fuse box may be the issue. Does anyone know what they are for? I read one is for the fuel pump but I couldn't find any info on the others. Also I am wondering if the idler pulley is bad and not putting the required belt tension on the alternator. Does anyone know what the belt deflection is supposed to be? If anyone has any ideas or experience with this issue i would appreciate your input.
Thanks in advance!
*Replaced the terminals
* checked the ground for continuity
* Fixed the frayed wire that hits the a/c line
* bench tested the alternator
* replaced the battery with a 850 cc amp one(although i am in Florida)
* Checked the alternator cable for continuity
* checked the #9 fuse
*switched the R05 Relay with the R03 one as I didn't have another relay to replace it with.
* Charged the Battery and had it tested again for verification at the parts store.
I am thinking that maybe one of the relays that are soldered to the fuse box may be the issue. Does anyone know what they are for? I read one is for the fuel pump but I couldn't find any info on the others. Also I am wondering if the idler pulley is bad and not putting the required belt tension on the alternator. Does anyone know what the belt deflection is supposed to be? If anyone has any ideas or experience with this issue i would appreciate your input.
Thanks in advance!
Laughing Gas
Joined: Jan 2003
Posts: 1,082
Likes: 40
From: Melbourne, FL
What are the symptoms of your charging issue? Is it just the idiot light on in the dash? I ask about the light because there's a diode in the alternator that causes the light to come on. I shorted a wire when changing my alternator, blowing the diode, causing the light to come on. It took me a trip to the dealership to tell me that. I took the alternator back to AutoZone (lifetime warranty), installed the new one and no light.
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What are the symptoms of your charging issue? Is it just the idiot light on in the dash? I ask about the light because there's a diode in the alternator that causes the light to come on. I shorted a wire when changing my alternator, blowing the diode, causing the light to come on. It took me a trip to the dealership to tell me that. I took the alternator back to AutoZone (lifetime warranty), installed the new one and no light.
Laughing Gas
Joined: Feb 2003
Posts: 877
Likes: 27
From: South Florida
" * Fixed the frayed wire that hits the a/c line..." What wire is this ? Was it shorting out on the A/C line or just rubbing on a rubber part of the A/C line ?
Are you the original owner ?
When you have the dash "charge" light on what voltage are you reading across the battery ? It could be an intermittent charge from the alternator, like it's on it's way out and might need to be replaced.
-Mike
Are you the original owner ?
When you have the dash "charge" light on what voltage are you reading across the battery ? It could be an intermittent charge from the alternator, like it's on it's way out and might need to be replaced.
-Mike
Postmaster
Joined: Sep 2010
Posts: 3,472
Likes: 2
From: Southern Cal
I have found that the OEM alternator lasts up around 150k. It looks like that's about your mileage but you don't state if still original.
To Mike's point, alternator brushes start to go bad and create an intermittent charge.
You first start out and it works fine but when it starts to warm up, it stops charging and you hope you get back home.
Last time this happened to me, all worked fine for the first 5 miles and barely kept it running with the little battery charge left.
I'm on our 4th alternator, although I've used the OReilly lifetime reconditioned.
Change your alternator and the problems fixed. No need to change the tensioner unless making noise. Pretty simple job under an hour.
To Mike's point, alternator brushes start to go bad and create an intermittent charge.
You first start out and it works fine but when it starts to warm up, it stops charging and you hope you get back home.
Last time this happened to me, all worked fine for the first 5 miles and barely kept it running with the little battery charge left.
I'm on our 4th alternator, although I've used the OReilly lifetime reconditioned.
Change your alternator and the problems fixed. No need to change the tensioner unless making noise. Pretty simple job under an hour.
Fleet Owner
Joined: Apr 2008
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From: 0,0,1
The problem is with the alternator. Either pull the alternator apart and clean the brushes and commuter rings, or replace the alternator.
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Thanks for the input! I didn't know that the alternators would give an intermittent issue I thought once they go that's it. I dont have the cash right now for a replacement so i will try cleaning it to buy some time(if that works) How do I clean the brushes? Do I use a wire brush or nylon brush? Any chemicals or just compressed air? I have never taken one apart before but I have fixed computer cell phones ect so I don't think it is beyond me to clean with some guidance.
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" * Fixed the frayed wire that hits the a/c line..." What wire is this ? Was it shorting out on the A/C line or just rubbing on a rubber part of the A/C line ?
Are you the original owner ?
When you have the dash "charge" light on what voltage are you reading across the battery ? It could be an intermittent charge from the alternator, like it's on it's way out and might need to be replaced.
-Mike
Are you the original owner ?
When you have the dash "charge" light on what voltage are you reading across the battery ? It could be an intermittent charge from the alternator, like it's on it's way out and might need to be replaced.
-Mike
It is a red wire with a green stripe i think I was shorting on the a/c (burn marks on the line) I traced it back to the wire harnes on the alternator. I am readin about 12.75v then it drops steadily to about 12v when I shut of the truck. This was after letting the battery charge again over night.
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Fleet Owner
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I did a little DIY write-up on it a while back: https://www.ford-trucks.com/forums/1...ery-light.html
So I ended up buying a new Alternator. So far so good. Thanks again for all the help!
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I wanted to give an update on the issue. With the new battery and alternator the truck is running good and not dieing. I can even leave the interior lights on while everyone is getting out with out worrying if the truck will start up again. Once again thanks for your help.
Postmaster
Joined: Sep 2010
Posts: 3,472
Likes: 2
From: Southern Cal
I wanted to give an update on the issue. With the new battery and alternator the truck is running good and not dieing. I can even leave the interior lights on while everyone is getting out with out worrying if the truck will start up again. Once again thanks for your help.
Fleet Owner
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Dang I think this thread jinxed me. Last night the wife comes home and says the battery light is shimmering on the navigator. Took it apart today, cleaned the brushes and commuter rings and all is well again. The brushes are almost all gone so I ordered a brush/regulator set. When this cold snap takes a break I'll have to pull the alternator again and swap them out.
Cargo Master
Joined: May 2001
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As the man said 150,000 miles is about it for these alternators. The brushs wear down. The brushes are not hard to change. But the big issue is the slip rings that the brushes run on are usually very badly grooved and some times worn through the copper cover. While the slip rings are replaceable it does take soldering skills and a fair size soldering iron to do this job.
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