Ford 6.0L Power Stroke Diesel :: 2003 - Alternator Won't Charging?
Oct 1, 2015
I have a 2003 F350 6.0. I had a flickering Battery lt on the dash last week so I replaced the Alternator. People recommended I upgrade to the 2005 140 amp alt from my stock 110. I have a single alt system. So I did, today it died on way to work. Batteries were drained. Had new alt checked and its fine. So All I have is a wiring diagram from 99-2002 but it shows the plug on the alt with 2 wires, Lt grn/red from switched ign and Org/Lt Blu which goes to batteries. Org/Lt blu has 12v but Lt green/Red has nothing with ign sw on. I did check fuse 45 in Central J box and have power there. I did notice I have no battery Lt on dash when you turn Ign sw on, and never got the Lt this morning when it died. What Im confused about is do I have a PCM? my diagrams that only go up to 2002 model show it for a 2 alt sys but not for a single alt. I should have power on Lt Grn/red with ign sw on correct? Everyone said 2005 alt was plug and play, the elec connector is now pointed down, where it was pointed up on the orig alt, look to be wired the same.
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I ve been noticing that the alternator isn't charging correctly, or at least it seems like it. We drive short trips sometimes two times a day, a mile or less. One day, night actually, I noticed it started to not turn over with it's usual enthusiastic sound. When the batteries get discharged to a certain point, the voltage at idle will be less than 12 volts. If I rev the engine for a bit, the volts jump up, but at idle it drops back to 12 or below. Seems to me that it should be at least 12v or above if the batteries are discharged, and more towards 12.5ishV if the batteries are fully charged.
After I put it on a 6A charger overnight, the voltage upon starting is above 12, sometimes over 13. But if the batteries start to dwindle down from short trips, the voltage drops to 12 or below at idle.
I did install the smaller pulley a few years back, and that worked massively. I couldn't get 12V at idle before installing the smaller pulley. But now it seems like I'm back to that same situation before installing the smaller pulley.
So, I m guessing that a alternator bench test is in my future? The batteries are fairly new, tho they have been down to nothing at least twice from boneheaded moves by yours truely!
And, I'm speculating that this charging situation contributed to the recent FICM replacement that I went thru.
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We've got a 2012 F550 6.7 with 138k. It recently got a battery light. The batteries are right around 12 volts with the truck running or off. I also tested the output on the alternator and its not charging. I put a new alternator in it and still no charge. All the connections are tight and clean. The batteries load test ok. Where to look next?
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One of my batteries on my van is on the frame rail. The box rusted out so I routed the battery into the back of the van for now. The van wouldn't start because the batteries were low. I charged the battery in the front engine bay overnight but it did not charge the 2nd battery, does that mean there's a disconnect between the two batteries? I thought they were in parallel.
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OK...I ask that you bear with me while I explain my question/issue.
I bought a used 2006 F350 Super Duty diesel last October (Oct 2015) and it has about 124,500 miles on it now. Last week, the power cut out as I was driving home from running an errand. Jumped it and got it back to the house. Suspected the alternator as both batteries tested low (according to AutoZone). Purchased the 110amp alternator and after a few days...I was able to get the alternator installed. AutoZone charged the batteries back up.
Today, I was able to start the truck and drive it around the block in order to make sure everyone was okay - before I took it out on the streets. Got back to the driveway....ABS light comes on, radio shuts off, odometer light goes off, etc. I shut the engine off and let it sit for a minute. Try to start it back up...and nothing happens. Ended up disconnecting both batteries while I ponder the root cause of the issue.
Is it possible the 110amp alternator is not strong enough to handle the power requirements (and that's why the dashboard lights went out)? To the best of my knowledge, there's only 1 alternator. The only "extra" that's installed is the tow/haul package (which I haven't used yet). According to the Ford Parts web site - after I enter the VIN for my truck - the results show a 110amp alternator (heavy duty alternator).
Would exchanging the 110amp for the 140amp be the most logical place to start? Or is there something I missed as a replaced the alternator?
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After 2yrs and 1mo, my DC power 270XP amp died. I put the almost 10 yr old factory alt back on and everything is good again, except for the glaring fact that I have a dead alternator. It is a month beyond warranty (of course).
Truck has been running great. Oil cooler, EGR bulletproof cooler, STC done in Dec at Ford due to high deltas. I have a small stereo - one 12" sub woofer, otherwise nothing that really stresses the electrical system. I did the "big three" with 1/0 copper - cost a fortune, saw no difference - but that could have been an issue for the alt.
I left a message today with etch support but did not get a call back. I hope they make good on this - I waited almost 4 mo's to get this thing and it was supposed to outlast my truck.
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i just had my 190amp DC Power Alternator just died. It was about 4 yrs old. I ordered a new Bosh AL7606 I know it's 140amp but it was half the price and in stock on amazon also lifetime warranty. I'm thinking of moving the pulley from the DC Power to the Bosh. Any thoughts? I went to the DCPower website but they were sold out and twice the price. I might just get the DC Revuilt as a spare?
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I have both a hydraulic dump trailer with two 12v batteries and an RV trailer with two 6v batteries to supply 12v. Both trailer's batteries are wired to be charged from the tow vehicle if the TV is equipped with a charge line.
Does the OEM 7 pin connector on a 2005 Ford 6.0 F250 CC 4X4 have a charging line on it? If so which terminal / pin is it?
What gauge of wire is it and how much amperage will it deliver to the connector? For testing, when is it hot? When the truck is running only? When the key is on? Is it hot all of the time?
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I just wanted to share with you all a cautionary tale about belt tensioners and idler pulleys. I am now a firm believer in installing the aforementioned items when you replace your drive belt. 15000 miles ago I replaced the drive belt and didn't heed the warning of some here on the forum.
For the last month or two I have noticed what sounded like road noise which I dismissed because I had just had new tires installed that had a more aggressive tread pattern than my previous tires, I also noted that the ECT had been a bit higher than normal, like running in the high 190's to low 200's on average.
Well while driving today I get the alternator warning light and lose power steering and soon after the brakes got stiff, this was followed by ever increasing ECT which got to 242* before I could get it off the road and shut down. It is too early to tell if the noises and the ECT temp rise were the result of this tensioner going out...
For what its worth the only tools required were a 10MM end wrench and a bit of skin to get the job done.
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Took in the alternator to get it checked and they said it was good. Put it back on and it seemed like it was charging according to my volt meter (14.24-13.5 v)
Today, it's not charging. Only reads 12.2 v while running. Is there a fuse or something I need to check? Grounds? It seems intermittent.
2003 F-250 V10 6.8 liter 255,000 miles.
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What this part it is? It sits over the alternator on the driver side and looks like a couple vacuum hoses plug into it. Mine is making a very loud buzzing noise.
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I have a 1997 Ford Expedition, 5.4. My research indicates that fuses 2. 19. 29 are associated with the instrument cluster (IC), could you identify their specific function in relation to the IC? My IC gauge lights are not showing and my alternator is not consistently charging. The blinkers, battery, oil, brake, and ABS indicator lights are showing in start. Regarding the alternator, my research indicates that a failing alt light on the IC may cause the no charging condition? As a note, I have a brand new battery, brand new alternator, brand new 3 pin wiring harness. Also, when the alternator is not charging and I connect the a jumper from the exciter wire directly to the pos battery terminal, the charging starts.
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I have a 06 F250 6.0 My battery light has been coming on. Doesn't stay on but I'm planning a trip back east and don't want any issues to occur. I was thinking maybe the batteries. So I stopped at the local Oreilly's Auto store and had them tested. Told the guy what it was doing and he said it sounded like the alternator. He tested it and said it was going bad. He also tested the batteries and said they were good. So I went looking for a replacement alternator and they have different amp sizes. So I'm not sure on what size the original one is and if the replacement should be a bigger size amp wise.
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2005 F-350 6L
Just changed my alternator, that was the easy part apparently...............
Cant get fan belt back on? My pulleys don't look the same as the picture under the hood. I can see a idler on passengers side down low, but cant seem to make it move to give me some slack.
What kind of tool to use on idler to get slack?
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I am having a charging system issue. The alternator is making barley over 12 volts. With KOEO the battery light on the instrument cluster does not come on. I have already replaced both batteries and the alternator -before i noticed the battery light is not coming on.
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About 5 months ago had a friend who I had to boost a bunch cause he kept leaving his lights on. his alternator was dead after a while and he borrowed my battery to get him to the service station. two weeks later my battery died. I bought a new battery from advance.
everything went fine other than a small headlight/tail issue that's been with the car since I bought it but never seemed to present itself other than one tail light never working and one headlight not working.
about 2 weeks ago i stopped at a filling station and my car wouldn't start.
battery checked good, alternator was bad. got a used alternator off of another volvo i own (same kind, reman off of a 1989 740GL) at first the alternator was reading low at 11.5 volts, i decided to chance it and it failed me on the highway, went back with a fresh battery the next day and drove it home. now I have since had the alternator at two places, at some old timer electro mechanic and he said it read 14.5...didn't trust him....went to the new autozone and they tested it as PASS at 14+.... put the alternator back on the car and it's still not charging.
the car runs fine other than it ain't charging. the alternator failure light is on, along with the two brake lights and bulb failure (which is to be expected because of particular system construction).
is there a fuseable link that might be burnt through? is there any other main voltage lines or regulators I should look for? main fuses?
1987 Volvo 740GLE 400,xxx miles. New Battery, 2003 Reman'd Alternator, 2004/5 replaced postive terminal and wire, countless number of small electrical flaws.
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So I have been having this little issue for a few weeks now. I will be driving along and out of nowhere my batt light will come on and my gauge cluster,radio and windows stop working and the ficim volts jump to 15.5-16.5. This is an intermittent issue. Yesterday I put my multi meter on the alternator and I am reading 13.5 or so this number was done at idle and the batt light was NOT on .
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My 2006 F250 has a single alternator and recently the charge light is on intermittently and I have watched output voltage fluctuate between 12.4 to 13.5 ... sometime a .3 volt bounce one way or another for no noticeable reason.
So rather than buy a new alternator, I would like to replace the voltage regulator and put in some new brushes.
What are part numbers that I need to pick up?
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My charging system light in my 2000 F250 keeps coming on and off and very random times. Its been happening for quite sometime now and I finally joined FTE so I figured I would ask everyone what could be causing this. Ive disconnected all the electrical plugs from the alternator and made sure they were in there well.
It all started when I was cleaning my engine not too long after getting the alternator replaced. I don't remember getting any water anywhere near the alternator and cant understand anything causing this other than the connectors. It will cut on and then cut right off sometimes and then sometimes it comes on and stays on...
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I am having an overcharging issue with my 2000 F350 diesel. It first started when I had a garage check the batteries due to poor starting this winter. They found one reading 6V and I had them replace it. After that the battery light came on. So I had them check it out again and they replaced the other battery. I can't remember if it started before or after the second battery but it started overcharging 16-17 volts according to the dash. I replaced the alternator still overcharging. Since then I have run a 4ga ground from one battery to the alternator and a 4ga ground wire from the other battery to the cab. I also checked most of the stock ground wires which all seem fine. Lastly, I also bought a ford alternator pigtail because one of the wires had cracked insulation and some corrosion. Currently it overcharges unless the battery light comes on which once it does the voltmeter in dash reads normal.
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Alternator locked up in a parking lot. Replaced it and had to replace pigtail due to a loose wire in the harness. Now battery light comes on intermittently. New alternator is doing fine producing anywhere from 13.9v to. 14.4v. No output voltage correlation to battery light at all. The belt is still in great shape so I don't suspect slipping. Fortunately I caught the old one locking up almost immediately and had recently replaced the belt. Output voltage looks great. Are there any fuses for alternator?
Only thing I can think of that I did...when splicing in the pigtail that connects to the alternator, I briefly grounded whatever wire in the pigtail is hot. Was just a split second, but enough to see a spark and maybe enough to blow a fuse? I've seen people reference an "under hood" fuse box, but I don't seem to have one. My truck is a 2002 CC with just over 100k on the clock.
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