Guys, many of you have seen several posts from me concerning my 2003 Expedition not charging the battery. I am pretty convinced that the problem is the fuseable link. I am posting this hoping that it might save somebody else from the pain. The fuseable link for my truck comes with the wiring harness. But it is not necessary to buy the whole harness. I nice guy from one Ford parts shop has pointed me to another parts shop that stocks just the link. Going to see tomorrow. Will post if that solves the charging problem.

 

Thanks Tedster9I have scraped the copper til it shines. I live in Tennessee. I think the problem is the fuseable link. Will know tomorrow. Will post results

 

No. Everything on dash is normal except the battery light is solid.

 

Need a charger for these tests, and to keep battery in good shape. Measure resting battery voltage (after charging) and also measure voltage directly at battery posts during actual starting. It should stay above 10 volts during cranking say. 9.6 volts is the limit. A good battery will probably stay above 11 volts. This tells you if the battery is OK generally. Sometimes measured at rest the battery will be "OK" but it cannot supply enough juice during the high current draw during starting.

Then let it idle with everything off except the engine itself. Should measure 13.8 to 14.3 volts something like that. This is normal alternater voltage at idle RPM, depends on how cold it is, and how depleted the battery is. Remember the alternator can not really re-charge the battery, not when there's a problem and we're testing everything and trying to troubleshoot and starting it 50 times in a row. What we remove from the battery has to be put back, no way around this. This is one reason to always have an external charger.

Then, anyway run the engine RPM up to 2400 and hold it there, and turn the high beam headlights on, the AC/Heater, radio etc. and then measure at the battery posts again. Voltage will sag some but should stay north of 13.8 volts DC or so. Here we loaded up the alternator and see if it can do the job. Both the battery and alternator need to be put under load to test.

 

Do you think the used alternator that you put on it could be faulty?

 

My 2003 has a new battery and new alternator. Alternator is charging at 14.2 volts. The issue is the check charging system warning light and the battery light on the dash or on. No codes help