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On my 2002, F250, PSD, my alternator went out at 85,000 miles. Dealer replaced it under warranttee. At 107,000, my alternator went out. Dealer replaced it for free as a prior warrattee issue. This week, with 126,000, my alternator went out. Dealer said there must be a problem "up stream". Couldn't find anything but a bad diode in the alternator. Charged me $200 (half price) for a new alternator plus $250 for 2 batteries and labor (rip off).
Question is, what's going on here. I'm not inclined to by a new $400 alternator every 20,000 miles.
I guess you don't have any add-on electrical gadgets or loads, or the dealer would have jumped on that as being the problem.
Have you been helping anybody out by jump starting them? Or do you happen to have an old tractor or something that you use the truck to jump start all the time?
The only outside load is when I tow a 5th wheel. There's a factory RV-7 plug in the bed and the 5th wheel hitch is always mounted so the dealer knows that this load is imposed on ocassion. They have said nothing about it. As for jumps, the only time that happens is when my alternator burns out and I need to get started to get to the dealer for a new one.
I haven't a clue what could be the problem then. Start hunting around for an automotive electrical shop. They still do exist in some areas. If it happens again, take the alternator to them, and they will rebuild it. It may be cheaper, and they may give some insight as to what actually happened inside the alt that went bad.
I can't see anything happening in the truck to blow the alternator out, without some sort of belt squealing or smoking wires.
Thanks: I hope that I don't need to go through this again but will take your advise about an electrical shop. Ford obviously doesn't know what to do but is tired of doing it for free.