Truck: '91 4.0 AT Ranger

Problem: Yesterday my truck wouldnt start when I was trying to leave work for lunch. I get one of the mechanics there to come over and mess with it... after tinkering a bit he crosses the solenoid while hitting something with a hammer and it starts up. So I go to lunch, come back, and later on go home for the day with no problems at all. This morning I get up to do my paper route and it wont start again. I was parked behind my wife's car so I put it in neutral to let it roll down the drive a little so I could get to the front of it. Well I crank it while its rolling and it starts. Now I shouldve just taken my wifes car, but I cant stand driving that little Kia for 3.5 hours, so I take my truck. As I'm driving I notice that the lights seem a little dim, but my radio and heat work fine so I dont think much about it. About halfway through, the lights get REALLY dim and I can no longer hear the blower motor, and the radio shuts off. So I start heading back home and then everything dies... no power at all, the engine bogs alot, shudders somewhat violently, and then dies as well. I managed to get it to the side of the road and then pushed it a little farther off to make sure it was safe. Needless to say it wouldnt even try to start afterward... With a jump it would just click once, and not try to turn over at all... just the click and then nothing.

My thought, for what its worth, and its not worth much, is that its the alternator... my knowledge is very limited, but I wouldnt think a battery problem would cause it to die like that... I dont know how much the starting thing is related... but it would seem that something is wrong with the starter as well. Pretty much I'm at a loss here, so any help would be GREATLY appreciated.

 

I agree with suspecting the alternator.

It sounds like it's not putting out enough to keep the battery charged, so you've likely run the battery compltely down, or you have a really bad set of battery cables, or connections on one, or both ends of the cables.

This could range from loose, to corroded, to cables with broken strands of wire inside the cables.

SO, you need to open the hood & begin a basic troubleshoot, looking for the obvious things, like the battery cables being loose or their connections being corroded, then see if the battery has the proper level of water & check it's state of charge with your digitial multimeter.

A fully charged battery, under no electrical load, should read 12.6 volts or higher. A battery reading of 12.06 volts is at 50% charge, 10.5 volts 0% charge.

If you find your battery is run down, but it's electrolyte is ok & the cables are ok, then suspect the alternator.

Pull it & have your favorite autoparts store test it's output under load, on their bench tester.

If you find it's bad & the battey is run down, DON'T install the new alternator & drive the vehicle to recharge the battery, as it could damage both.

Check the batteries water level if you have access to the cells & top them off with distilled water, then have the battery recharged SLOWLY, over night, using a good battery charger, so it doesn't get the electrolyte & plates too hot & cause further damage.

Once you get the battery fully recharged, install it & take the vehicle back to the autoparts store & have them do a complete electrical system checkup, with their portable electrical system tester, to make sure all is well.
Most autoparts tores will do this at no charge, if your having problems.

Let us know how it goes.

 

Just a question. Did you happen to notice while all this was happening if your red battery idiot light came on on your dash? Or did your charge gauge (if you have one....I do) drop to 0? On my '93 when my alternator went, I too, noticed headlights dim, blower motor start getting quiet, etc. I instinctively looked at the charge gauge and it was flatlined at 0. But when I got a jump, it did start right up...no clicking. But it died once again by the time I got home. You mentioning the tapping on something with a hammer and shorting across the solenoid has me stumped on an alternator failing, though. Sure it wasn't the starter he was rapping on? I've seen shorted starters act funny at times, and drain batteries as well. I've also remember hearing something about a recall on the 93 and up ignition switch. Check the recalls on this one. Not 100% on this but that could also cause a discharge problem. But I agree with Pawpaw and he has some really good starting suggestions for you. Those cable ends are the most notorius reasons why replacement alternators and batteries are sold, many times running up a $500 bill at the garage! All over $10 cables! Yes, it happens! But, if the alternator needs to be replaced and you are handy and have a few days to spare (thank goodness for that KIA!), you can check EBAY and find a replacement with a warranty for a good price. I saved $400 on my 4 wheel drive solenoid when I replaced that last year. Also consider replacing your serp belt if you pull the alternator. You might want to call around to a few repair shops and get pricing from them in advance of committing to just one shop. Most have free towing if you need to get the truck to the shop. And yes, please let us know how you made out. Be interesting to find out what went wrong. Good luck!

 

also when you have the alt tested it should put out atleast 14V, but NO MORE than 15. even though its a 12V system the alt has to put out 14V. 13.9V or less you need a new alt. i had a 87 T-bird that i nursed off the battery bc of a bad alt and did not have the money to buy one at the time. so i come home from work and charge the batt. and then go to work in the morn. i had a local parts dealer bench test the alt and it put out 13.7V enough to run good they said.. WRONG.. so i ended up getting new alt and batt.

 

Update: I got the truck back home via a tow company about 4 hours ago. The first thing I check is the battery... it was low at 11.56 (I think) on the meter. I charge it up a bit with the Kia and even after trying to get it to start over the last few hours, it reads at 12.45 after the charge, so I dont think that the weak link. I finally now have the floor jack at the house (had to go get it when my wife got back from picking up the kids she watches) and so now I can jack it up and see if there's anything obviously wrong with the starter as far as something being loose, etc... The the battery terminals were pretty dirty and connectors are pretty corroded, so I picked up new ones on the way home, just because they're cheap and easy to replace :P As far as the alternator... I think I know what the guy from work was beating on... don't ask me how that got it started yesterday... maybe it rattled something else just enough to do the trick... I dont know. I was sitting in the truck at the time so I couldnt see. But its beat to hell... the outside of it is actually cracked and the sort of lip that surrounds the little fan lookin part of it has a piece broken off of it... so I dont think I had an alternator problem until yesterday... so that needs to be replaced regardless of everything else I figure... even so, I'll take it to schucks and see what they say... same with the starter... might as well get them tested before spending the money... I'll most likely replace the battery as well, because it is 9 years old I just found out lol.

Oh and barkeep, yeah the red charge light came on and the gauge dropped to 0. The check engine light came on as well. Anywho, I'm headed back out there... I'll keep ya updated

 

Kin...if your battery is 9 years old, that could very well be the problem. If the alternator is working and the battery is not taking a charge, you'll end up with what you are seeing. Good to replace the cable ends, too. Start with the cheap less labor costly parts to replace. They are usually the weakest link. Its funny b/c now that you mention it with the battery that old, I'd replace the battery just so. It will leave you sitting sooner or later. Production run lead acid batteries I've seen last 6 years tops. You've been lucky, mate! If the alternatoe is now damaged...check with a junk yard for an OEM unit. 91's are still around. And the alternate is not that big of a job to replace. Just be sure to mark where everything goes...and you'll do fine. The waterpump was a hard tho! Phew! Keep your buddy with the hammer away from THAT thing! Good luck!

Oh...and most likely your starter and solenoid are fine. I've never had a problem with either unless you crank the motor excessively.

 

Final Update: Everything is all good now... first I replaced the starter... I figured that the starting problem was seperate from the charging problem... first one I installed turned out to be one for a manual... dumb counterguys caused me a big headache haha... after getting the right one in, it fired right up (Note: I had a battery charger on it overnight, to make sure it would have enough charge). Next day I took it down to Schucks for the electrical test, and they said that it was the alternator, and that the battery was still very healthy... however I replaced both anyhow. After wrestling with the belt until I found about the tensioner dealy I got it all together, and everything seems to be doing well. All my lights inside and out are much brighter than they ever were. The true test was driving it for my paper route this morning before work, and it had no problems whatsoever. Thus ends my first adventure in vehicle repair and maintanence. Oh and btw, thanks for the help and support!

 

OK, good feedback & good wrench turning Kinville, you've been busy on this puppy, good to hear you go er put right!!!!

Good idea to take it & have the electrical system checked out. Running electrical things at low voltage puts extra strain on them & weakens them.

Now that you've broken the ice & become a "wrench turner", think about investing in a repair manual for our ride, it'll likely pay for itself the first time you use it. Mose things you can do yourself & save a bundle of $$$$$$!!!! Plus you'll get a lot of satisfaction knowing you did it yourself, like this first time!!!! Makes you feel good when you win one once in a while doesn't it!!!!

I still remember the first time I got the courage to turn my first wrench, been addicted to the feeling ever since!!!! LOL

 

haha yeah I'm ready for more... it feels great getting it healthy again... plus its so much nicer driving my ranger rather than the little nissan truck I borrowed. Also, its a nice bonus that its better than before it started having problems... btw I already had a repair manual... but its just one of those haynes ones... not too helpful... but better than nothing for sure...