Alternator / Battery > Charging problems
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99 Expy XLT 5.4L ALt will not charge draining my battery any suggestions ?
Help !!!!
99 Expy XLT alt was replaced about two weeks ago. Everything seemed ok, while driving vehicle my instrument and panel lights
started to dim. Next morning battery was noticeably weak, replaced battery. So i replaced the battery with a brand new one i lucked up and found this website. Which led me to checking all my fuses, i had one blown it was a 10 amp fuse on the left side of the box can't remember which one it was.
Anyway i replaced my belt with a new one the old one was in decent conditon. Now my new battery won't even start the car/truck/suv (She's all three to me). I noticed a clicking noise coming from my engine compartment. I beleve the two relays in this little black box are bad but i'm not sure how to test them Autozone did'nt have the equipment to test them. What function do they serve? How many fuse boxes are assoc. with my charging
system and where are they located ? Also my rear wiper motor is not working i checked the fuse box and all fuses were in good shape any ideas about this ?
I'm a newbie just wanted to give as many details as possible,
sorry so long.
99 Expy XLT alt was replaced about two weeks ago. Everything seemed ok, while driving vehicle my instrument and panel lights
started to dim. Next morning battery was noticeably weak, replaced battery. So i replaced the battery with a brand new one i lucked up and found this website. Which led me to checking all my fuses, i had one blown it was a 10 amp fuse on the left side of the box can't remember which one it was.
Anyway i replaced my belt with a new one the old one was in decent conditon. Now my new battery won't even start the car/truck/suv (She's all three to me). I noticed a clicking noise coming from my engine compartment. I beleve the two relays in this little black box are bad but i'm not sure how to test them Autozone did'nt have the equipment to test them. What function do they serve? How many fuse boxes are assoc. with my charging
system and where are they located ? Also my rear wiper motor is not working i checked the fuse box and all fuses were in good shape any ideas about this ?
I'm a newbie just wanted to give as many details as possible,
sorry so long.
Post Fiend
Joined: Apr 2002
Posts: 7,157
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From: Central Kali
Hi and welcome to FTE. 
The manual says to check the 20 amp mini fuse in the power distribution box. (not very clear instructions)
Next is to check for battery voltage at the alternator B+ terminal.
Next is to measure pin c of the alternator 3 pin connector for battery voltage. This is the left pin if the widest part of the oval is up looking at it.
Next test is to measure the alternator I terminal (lg/r). Should be above 1 volt.
Next test is to ground the F pin on the alternator/ regulator. If battery voltage goes up, replace the regulator. If not, replace the alternator.
This would be easier if you had the cd service manual. I hope that I helped.
The manual says to check the 20 amp mini fuse in the power distribution box. (not very clear instructions)
Next is to check for battery voltage at the alternator B+ terminal.
Next is to measure pin c of the alternator 3 pin connector for battery voltage. This is the left pin if the widest part of the oval is up looking at it.
Next test is to measure the alternator I terminal (lg/r). Should be above 1 volt.
Next test is to ground the F pin on the alternator/ regulator. If battery voltage goes up, replace the regulator. If not, replace the alternator.
This would be easier if you had the cd service manual. I hope that I helped.
Logistics Pro
Joined: Jul 2003
Posts: 3,595
Likes: 52
From: Lawton, Oklahoma
Fuse number 11, at the power distribution box under the hood, and the large black with orange striped wire at the back side of the alternator should both have 12V. Also check fuse 30, a 30 amp fuse in the interior fuse panel. All these must have power for the alternator to operate. Dont think that just because you just replaced the alternator that it cant be bad. I get bad ones out of the box regularly.
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Update,
I've been able to make some progress, all of my fuses are good
i measured the 20 amp fuse (#11) and got 11.7 volts, then i measured the black and orange striped wire and got zero ..
Question where are the elusive MEGA FUSES Located ? There is a black cover thingy underneath my starter relay are the fuses inside of the harness?
In the Haynes Manual these 175 amp fuses are in plain sight BUT
not on my EXPY !!! My volatage with the vehicle off was about 12.5 then i started it up ND TURNED ON THE HEATER FRONT AND REAR MY HEADLIGHTS AND RADIO, BATTERY STARTED TO DRAIN A LITTLE AS EXPECTED.
I hope that theses MEGA Fuses solve the problem just don't know where they are. Changing the plugs on her has proven to be eaiser then finding these DARN FUSES !!!!!!!
ANd i'm talking about that number 4 PLUG TOO thats right, i thought after that i would have graduated to the big leagues but
i still have that ROOKIE THING going.
Sorry so lenghty just venting a little thanks for all the help
I've been able to make some progress, all of my fuses are good
i measured the 20 amp fuse (#11) and got 11.7 volts, then i measured the black and orange striped wire and got zero ..
Question where are the elusive MEGA FUSES Located ? There is a black cover thingy underneath my starter relay are the fuses inside of the harness?
In the Haynes Manual these 175 amp fuses are in plain sight BUT
not on my EXPY !!! My volatage with the vehicle off was about 12.5 then i started it up ND TURNED ON THE HEATER FRONT AND REAR MY HEADLIGHTS AND RADIO, BATTERY STARTED TO DRAIN A LITTLE AS EXPECTED.
I hope that theses MEGA Fuses solve the problem just don't know where they are. Changing the plugs on her has proven to be eaiser then finding these DARN FUSES !!!!!!!
ANd i'm talking about that number 4 PLUG TOO thats right, i thought after that i would have graduated to the big leagues but
i still have that ROOKIE THING going.
Sorry so lenghty just venting a little thanks for all the help
Logistics Pro
Joined: Jul 2003
Posts: 3,595
Likes: 52
From: Lawton, Oklahoma
There should be a black plastic cover on the passenger side firewall next to the battery. Remove that plastic cover and you should see the mega fuses and starter relay.
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ok,
removed the black cover that hides the starter relay there was this metal box thingy, with three wiring harnesses one medium black, and two bigger ones.
i thought these would be the megas but to no avil, they appear to be wiring harnesses only. unless that peice with the 10mm bolt in it is the mega fuse, i don't see a way of disconneting this from the vehicle with out tearing something up!
the piece with the 10mm bolt is attached to the black metal frames and in no way do i believe i'm close to solving this problem.
the only other area is a black cover that runs from one side of the expy to the other. it has four screws and about five metal clips that secure it.
do i dare remove this piece and continue dismantling my baby ? i 'm just about to take the 20's off and just roll them around myself (lol) !!!!
call me slow but this seems so easy to figure out but......
i'm at a lost need help any advise is welcome. i'm looking for two fuses or is that harness thingy the problem.
one more thing the bolt seems perm. attached to the harness which as i said is attached to the metal frame.
it's miller time for now luckly shes in my garage just listing (lol)....
Upper Case Edited out by FTE Admin...for ease of reading
removed the black cover that hides the starter relay there was this metal box thingy, with three wiring harnesses one medium black, and two bigger ones.
i thought these would be the megas but to no avil, they appear to be wiring harnesses only. unless that peice with the 10mm bolt in it is the mega fuse, i don't see a way of disconneting this from the vehicle with out tearing something up!
the piece with the 10mm bolt is attached to the black metal frames and in no way do i believe i'm close to solving this problem.
the only other area is a black cover that runs from one side of the expy to the other. it has four screws and about five metal clips that secure it.
do i dare remove this piece and continue dismantling my baby ? i 'm just about to take the 20's off and just roll them around myself (lol) !!!!
call me slow but this seems so easy to figure out but......
i'm at a lost need help any advise is welcome. i'm looking for two fuses or is that harness thingy the problem.
one more thing the bolt seems perm. attached to the harness which as i said is attached to the metal frame.
it's miller time for now luckly shes in my garage just listing (lol)....
Upper Case Edited out by FTE Admin...for ease of reading
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Logistics Pro
Joined: Jul 2003
Posts: 3,595
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From: Lawton, Oklahoma
Ok I just went out and looked at my 99 F150 5.4 and it appears that the mega fuses are not used on the later models. Must have only been on the 97-98. That large blac with orange stripe power lead from the alternator goes directly to the starter relay now at the bottom post of the relay. The power cables off the battery have the fusible links inline to the cables themselves. If you look about 8 inches down from the postive battery post you will find about an 8 inch long black plastic shield covering the fusible links. The plastic cover even says on it "Fusible link". Do a continuity/power check on them as there are two of them there. I would recheck that power wire to the alternator again, both at the starter relay end and at the alternator post. Those are some very large links to blow but a really badly shorted alternator could blow one.
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i'm on it man !!!! thanks for the help i'll let you know how it turns out.
Edit:
opps forgot if links are bad should that be visible to the eye burned or split or something.......
* Upper Case Edited out by Admin.
Edit:
opps forgot if links are bad should that be visible to the eye burned or split or something.......
* Upper Case Edited out by Admin.
Logistics Pro
Joined: Jul 2003
Posts: 3,595
Likes: 52
From: Lawton, Oklahoma
Not necessarily. Just take a grounded test light and ***** the battery post side to ensure you have 12v on that side, then ***** the opposite side and it too should light 12V and bright. An multimeter can be used in the same manner. You dont necessarily have to take it apart to see if it has continuity. I would only disassemble it if it has no continuity. I could be burned in two or just broken under the sheathing. I didnt take mine apart to see what type it has so YOU will get to be the one to report on that. Mine arent bad so Im not chopping into it to see.. 
Mine arent bad so Im not chopping into it to see..
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Fusable links are okay voltage regulator seems to be the culprit
i'm headed out to the nearest late night autozone to try and have it replaced. Will let you know how it turns out. I really appreciate the help, i understand completely how my charging system functions now.
i'm headed out to the nearest late night autozone to try and have it replaced. Will let you know how it turns out. I really appreciate the help, i understand completely how my charging system functions now.
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Many Thanks man the problem was the alt. I had just purchased
a remanf. didn't think it would be bad. But i learned a valuable lesson about my charging system. I can now locate all of the fuses involved with my charging sys. I can tell you that the 99 EXPY don't have Mega Fuses, they have a fusable link(s) that run directly to the starter relay then to the alt. If i see any future post on this one i feel that i can help someone like you helped me
Thanks again.................
a remanf. didn't think it would be bad. But i learned a valuable lesson about my charging system. I can now locate all of the fuses involved with my charging sys. I can tell you that the 99 EXPY don't have Mega Fuses, they have a fusable link(s) that run directly to the starter relay then to the alt. If i see any future post on this one i feel that i can help someone like you helped me
Thanks again.................
Logistics Pro
Joined: Jul 2003
Posts: 3,595
Likes: 52
From: Lawton, Oklahoma
Glad to hear you got it squared away. Its most unfortunate but I think about 5-10 percent of remaned alternators and starters go bad the first year in the aftermarket. Its just a good thing that the alternator is relatively easy to install on your Expy. Congrats on the successfull venture.
Its most unfortunate but I think about 5-10 percent of remaned alternators and starters go bad the first year in the aftermarket. Its just a good thing that the alternator is relatively easy to install on your Expy. Congrats on the successfull venture.
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