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This seems to be a reoccuing porblem for my truck. Maybe somebody can shed some wisdom but as of right now I don't know. I will be more technical when I have more time to post. But I was fiddling with my horn and it caused a large discharge of the battery and the voltage regulator seems to be stuck open causing a overcharging situation. This has happened to me before and I have fixed the wiring and the grounds. When I change the voltage regulator to a diffrent one I get no charging at all. Two wires are hot while the engine is running on the voltage regulator plugin. The stator and ground are connected properly and the power wire is good.
Would this cause a fairly serious over-charge issue. The horn relay sounds like a good place to check though thanks. Just out of curiosty would a ford 1-G, 2-G, 3-G or 4-G alternator bolt up to the old 302 brackets. Im pretty sure it would and these can be bought as internally regulated alternators too.
There is an article in next month's 'classic truck' magazine "all charged up" may find informative. Many of the current articles can be reviewed on their website, will need to wait until next issue, Jan./07, is posted. There is also a Q&A section. In meantime, may want to see if able to locate issue in local news stand and review to determine if any help.
Recently went to the ford 3g alternator on my 390,it bolted right in. I understand they were used on mustangs?...It is a one wire style alt. looks good, works good and I found it on eBay from "LOAD BOSS" "ALTERSTART SYSTEMS, Inc." You may even be able to find a 3g at the wreckin' yard.
Yeah the junkyard is full of cars that have these:
3G 130amp Donor Vehicles:
(1994-95) Ford Mustang 5.0L
(1994-00) Ford Mustang 3.8L
(1994-97) Ford Thunderbird, Mercury Cougar 3.8L
(1990-95) Ford Taurus, Mercury Sable 3.8L
(1993-99) Ford Taurus, Mercury Sable 3.0L
(1995-98) Ford Windstar 3.8L & 3.0L
(1991-94) Lincoln Continental 3.8L
(1992-97) Ford F Series Pickup
(1992-96) Ford E Series Van