alternator wire harness ?
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Senior User
Joined: Dec 2007
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alternator wire harness ?
hey guys
recently my alternator started on fire and I believe it was a combo of the alternator and the wiring harness. I put it out before any other damage was done. I have a 93 f250 351 and I can't find the harness anywhere, ford discontinued and no other places like napa, rock, or carquest have it. Can I rebuild the harness? Anyone have one for sale?
recently my alternator started on fire and I believe it was a combo of the alternator and the wiring harness. I put it out before any other damage was done. I have a 93 f250 351 and I can't find the harness anywhere, ford discontinued and no other places like napa, rock, or carquest have it. Can I rebuild the harness? Anyone have one for sale?
Logistics Pro
Joined: Mar 2005
Posts: 4,698
Likes: 47
From: Mexico, Missouri
2 possible fixes:
1. Find a salvage yard that can get the harness from the older trucks
2. Do a 3g alternator upgrade. Might be a better alternative since the older 2g's had more resistance. You could also pick up a 3g from a salvage yard for $50 and have less than a hundred in the upgrade.
I know i have seen the harness somewhere, but it may be completely unavailable now. Maybe some others have a better solution.
You could maybe match the wire size with new and insulated terminal's.
1. Find a salvage yard that can get the harness from the older trucks
2. Do a 3g alternator upgrade. Might be a better alternative since the older 2g's had more resistance. You could also pick up a 3g from a salvage yard for $50 and have less than a hundred in the upgrade.
I know i have seen the harness somewhere, but it may be completely unavailable now. Maybe some others have a better solution.
You could maybe match the wire size with new and insulated terminal's.
pedant
Joined: Jan 2008
Posts: 23,576
Likes: 38
From: EXTREME southwest CT
Is the entire harness burned up?
Almost any autoparts store sells a replacement pigtail/plug assembly because 2G failures are quite common.
Borg-Warner PT-780
Standard Motor Products S-542
Power Plug 4628011
KEM Parts 350-220
Pico 5711
Dorman/Motormite #85123 / 08622
etc.....
Upgrade to a 3G alternator and get rid of the charging plug that melts and burns up your truck
Try Ryan McCormick @ RJM Injection Tech
RJM Injection Tech Alternator Accessories & Parts
Almost any autoparts store sells a replacement pigtail/plug assembly because 2G failures are quite common.
Borg-Warner PT-780
Standard Motor Products S-542
Power Plug 4628011
KEM Parts 350-220
Pico 5711
Dorman/Motormite #85123 / 08622
etc.....
Upgrade to a 3G alternator and get rid of the charging plug that melts and burns up your truck
Try Ryan McCormick @ RJM Injection Tech
RJM Injection Tech Alternator Accessories & Parts
pedant
Joined: Jan 2008
Posts: 23,576
Likes: 38
From: EXTREME southwest CT
Buy the $8 pigtail and bring the alternator in to get tested.
9 times out of 10 it is just the plug end of the harness.
http://www.rjminjectiontech.com/?p=10
9 times out of 10 it is just the plug end of the harness.
http://www.rjminjectiontech.com/?p=10
There is a Ford TSB on this very subject. It even mentions a part number for a kit to fix the harness. Looks like you could order the kit and be on your way.
Ford TSB 96214, applies to F150 through F350, model years 1986 through 1994
(The TSB also applies to numerous other car and truck models)
ISSUE:
When a generator fails, there are a few failure modes that may cause heat to be produced at the wiring harness-to-generator connector. This excess heat may damage the female terminals on the wiring harness, resulting in increased resistance. The increased resistance produces more heat. When the generator is replaced, the resistance produced by a damaged connector may damage the new generator and could result in a repeat repair, including installation of another generator. High resistance (caused by a damaged connector) will not go away until the damaged connector is replaced.
ACTION:
Visually inspect the harness-to-generator connector for damage (heat, corrosion, distortion and cracking) before installing a new generator. Install the Generator Wiring Harness Connector Kit (E5AZ-14305-AA) if the harness-to-generator connector is damaged.
The Generator Wiring Harness Connector Kit (E5AZ-14305-AA) contains the following:
^ One (1) Red Wire Butt Connector
^ Two (2) Yellow Wire Butt Connectors
^ One (1) Wire Connector Assembly
^ One (1) Instruction Sheet (I.S. 6849)
Ford TSB 96214, applies to F150 through F350, model years 1986 through 1994
(The TSB also applies to numerous other car and truck models)
ISSUE:
When a generator fails, there are a few failure modes that may cause heat to be produced at the wiring harness-to-generator connector. This excess heat may damage the female terminals on the wiring harness, resulting in increased resistance. The increased resistance produces more heat. When the generator is replaced, the resistance produced by a damaged connector may damage the new generator and could result in a repeat repair, including installation of another generator. High resistance (caused by a damaged connector) will not go away until the damaged connector is replaced.
ACTION:
Visually inspect the harness-to-generator connector for damage (heat, corrosion, distortion and cracking) before installing a new generator. Install the Generator Wiring Harness Connector Kit (E5AZ-14305-AA) if the harness-to-generator connector is damaged.
The Generator Wiring Harness Connector Kit (E5AZ-14305-AA) contains the following:
^ One (1) Red Wire Butt Connector
^ Two (2) Yellow Wire Butt Connectors
^ One (1) Wire Connector Assembly
^ One (1) Instruction Sheet (I.S. 6849)
pedant
Joined: Jan 2008
Posts: 23,576
Likes: 38
From: EXTREME southwest CT
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Hotshot
Joined: Sep 2001
Posts: 11,958
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He may already have a 3G according to this. What was really the first year for it in the F150?
http://www.fullsizebronco.com/forum/...ght=alternator
http://www.fullsizebronco.com/forum/...ght=alternator
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Postmaster
Joined: Dec 2007
Posts: 3,052
Likes: 1
From: Jacksonville FL
Thats a good question.. I thought 93 was when they got them. 
EDIT:
"If you have an 87-92 302 or 351W: you have a 2G alternator"
"93-99 narrow-eared non-DOHC Taurus
94-95 V8 Mustang
94-00 V6 Mustang
94-97 V6 T-Bird/Cougar
95-98 Windstar
91-94 V6 Lincoln Continental."
"For a 130 amp, you can get that for a:
93-96 V8 Econoline with Air Conditioning or the High Output Alternator options
97-03 V6 Econoline E-Series or F-150
95-01 4.0 V6 Explorer or Ranger"
http://fullsizebronco.com/forum/show...ght=alternator
EDIT:
"If you have an 87-92 302 or 351W: you have a 2G alternator"
"93-99 narrow-eared non-DOHC Taurus
94-95 V8 Mustang
94-00 V6 Mustang
94-97 V6 T-Bird/Cougar
95-98 Windstar
91-94 V6 Lincoln Continental."
"For a 130 amp, you can get that for a:
93-96 V8 Econoline with Air Conditioning or the High Output Alternator options
97-03 V6 Econoline E-Series or F-150
95-01 4.0 V6 Explorer or Ranger"
http://fullsizebronco.com/forum/show...ght=alternator
Thread Starter
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Senior User
Joined: Dec 2007
Posts: 104
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Buy the $8 pigtail and bring the alternator in to get tested.
9 times out of 10 it is just the plug end of the harness.
RJM Injection Tech Pigtails:
9 times out of 10 it is just the plug end of the harness.
RJM Injection Tech Pigtails:
which one? Do you mean the 2G Alternator pigtail - $20 or the
<table><tbody><tr><td>3G Alternator</td> <td> <select name="os0"><option value="Pigtial">Pigtail</option><option value="Connector">Connector w terminals</option></select> </td> <td> - $10</td></tr></tbody></table>
Postmaster
Joined: Dec 2007
Posts: 3,052
Likes: 1
From: Jacksonville FL
which one? Do you mean the 2G Alternator pigtail - $20 or the
<table><tbody><tr><td>3G Alternator</td> <td> <select name="os0"><option value="Pigtial">Pigtail</option><option value="Connector">Connector w terminals</option></select> </td> <td> - $10</td></tr></tbody></table>
<table><tbody><tr><td>3G Alternator</td> <td> <select name="os0"><option value="Pigtial">Pigtail</option><option value="Connector">Connector w terminals</option></select> </td> <td> - $10</td></tr></tbody></table>
Well do you have a 2G or 3G alternator? Is the fan internal or external?
pedant
Joined: Jan 2008
Posts: 23,576
Likes: 38
From: EXTREME southwest CT
If Rich had a 3G alternator I doubt it would have burned.
The single charge lead mounted on a stud was Ford's solution to an undersized harness that corroded and then melted because of the increased resistance.
Here's a comparison photo:
My info says the 2G alternator pigtail fits F-150's up to 1994.
Add another manufacturer to the alternator harness repair pigtail list...
Alternator Connector by Motormite - Part 85123/08622 - Advance Auto Parts
I don't mean to push the Ford Fuel Injection products. It's just that there's such a wealth of knowledge and photos there it's easy to refer to Ryan's website.
I don't draw too much current, but can appreciate the fact that my 3G puts out more at idle than the old 2G did at redline. And after diagnosing dead batteries too many times (my plug shorted and was replaced 3 times, never caught fire)
I ordered the conversion harnesses and bought a NIB 3G off Ebay for under $75 delivered.
I'm happy I won't set fire to my truck and I'm not looking back
The single charge lead mounted on a stud was Ford's solution to an undersized harness that corroded and then melted because of the increased resistance.
Here's a comparison photo:
My info says the 2G alternator pigtail fits F-150's up to 1994.
Add another manufacturer to the alternator harness repair pigtail list...
Alternator Connector by Motormite - Part 85123/08622 - Advance Auto Parts
I don't mean to push the Ford Fuel Injection products. It's just that there's such a wealth of knowledge and photos there it's easy to refer to Ryan's website.
I don't draw too much current, but can appreciate the fact that my 3G puts out more at idle than the old 2G did at redline. And after diagnosing dead batteries too many times (my plug shorted and was replaced 3 times, never caught fire)
I ordered the conversion harnesses and bought a NIB 3G off Ebay for under $75 delivered.
I'm happy I won't set fire to my truck and I'm not looking back