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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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Dumb founded? 1990 F150 Alternator change

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Old 12-13-2017, 10:29 AM
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Unhappy Dumb founded? 1990 F150 Alternator change

I stroded into the my shop one day while leaving the 1990 f150 run. I came back out 5 minutes later and smelled electrical wiring. I stopped the engine and looked around. couldn't see anything at first so I restarted only it would not start- battery was dead. Now I know the battery went dead running the truck as the alternator stator plug was burnt. This, in turn, melted the fuse link wire that is welded to the end of the two power leads ( black) and the yellow lead from Voltage regulator. All in one harness from the alternator to solenoid. The Green from voltage regulater goes to a link ( fuse link?) It is a plastic gizzmo, which has wire slip connector inside. This green voltage regulator wire then heads off into the main harness to the other side of truck. The white wire comes out to regulator and back into stator.
I rewired the fused wire to the solenoid with regular 20 strands 16 ga wire to the two black and yellow wires. Now the big question. My fuel pumps will not start. This is the second alternator. The first I replaced and did not see the burnt fuse wire, the battery was not charging. Started fine and fuel pumps worked. So I took the alternator back to Oriellies and got a different one. When doing the second swap I decided to do Ohm testing on the harness and found the burnt wire. Everything is back together the way it came apart. I even swapped new fuel relay and eec relay. question is: what is that plastic gizzmo on the green wire?
Did I break something when I took it apart? What is the little 1/2 by 1 inch metal box next to solenoid - has black wire running to and from (2) 3/8 " studs. Looks like it may be a breaker of sorts. One time I had 000 ohms and now nothing.
 
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