Ford 7.3L Power Stroke (1999-2003) :: Charging System Light Goes On And Off Randomly
Oct 14, 2008
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 have a 99 f350 7.3l 4x4 and my battery light flickers randomly. I have checked the alternator and both battery's. All brand new and seems to be ok. They only are getting a charge when the battery light is flickering. I put both new batteries in on Thursday and on Sunday I needed a jump at the store.
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I have a 2000 f250 with the 7.3 and 181,000 miles on it, recently got stuck in the snow (in 2wd because i forgot to lock the hubs) and the rear wheels did alot of spinning. Now i randomly have the OD light start to blink, sometimes its a half a blink, sometimes it'll stay on for a few seconds, itll do it randomly while crusing down the road at a constant speed, also noticed my rpms fluctuate a tad at idle.
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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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I just changed the drain valve on the fuel filter bowl. All went well and no more leak, but now I am getting an "emission system" warning light.
After I replaced the valve, I filled the fuel bowl with diesel fuel. Was there any other priming that needed to be done (if any)? What the emission system warning light may mean?
2002 F250 7.3L 4x4.
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So the truck has been stalling out and dropping power randomly, symptoms pointed to needing the 50 cent mod, changed the cps for cheap insurance and peace of mind just in case it wasn't the uvch, no dice. So last night I yanked valve covers for the first time here's what I did while I was under there, check my work.
1st I ohmed out injectors thru the 42pin harness according to tuglys sig link. My meter would only go down to a 0.4 when testing the test leads just to each other
DS injector ohms
#2 3.5
#4 3.4
#6 3.6
#8 3.6
PS injector ohms
#1 3.6
#3 3.6
#5 3.5
#7 3.6
DS glow plug ohms
#2 prong to ground 2" away 0.9 ; white connecting wire back to gp relay 0.3
#4 0.9 wire to relay 0.5
#6 infinity ohms up thru highest meter setting, checked multiple times and different ground spots,(replacing tonight) wire to relay 0.5
#8 0.5 wire to relay 0.5
PS glow plug ohms
#1 1.0 ; white wire back to relay 0.6
#3 infinity multiple tests as well (replacing tonight) wire to relay 0.5
#5 0.9 wire to relay 0.6
#7 1.0 wire to relay 0.7
Next up, ebp sensor was reading 1.9 higher than map/baro koeo, gently cleaning sensor earlier didn't work. Installed new motorcraft, will check it with Torque pro koeo once the batteries are reconnected
Next I checked the uvch connections which felt good, darn it, maybe a smidge of movement from the DS, but nothing halfway disconnected or anything. Hmm. I ground down the quarters to the top of his head and installed.
Next I torqued down the 4 bolts per cylinder of the rocker arms at 20 ft/lbs, all were perfect and snug
Next up, injector torque. I've read on here below 50, or 80 in/lbs depending on different threads and opinions that I would need to replace o-rings.
So I set the in/lb click torque wrench at 50 in/# and tested the wrench's click on the higher torqued rocker bolts, then checked all the injectors, all were good
Reset for 80in/lbs, tested, then hit all injectors, #6 almost budged but clicked immediately before the handle moved
Reset for 100 in/lb, tested on larger bolt, 2 injectors took a 1/8 turn;
Reset for official spec of 120 in/lb , tested wrench, all injectors took 1/3 to 1 full turn
Reset for 130 in/lb (above official spec, but highly recommended on here by those way more knowledgeable than me on our engines) tested on a larger bolt, slowly and carefully gave all injectors almost an extra 1/2 turn to click; whew, finally a relaxed sphincter.
At this point I knew I needed to buy 2 glow plugs today, replace, then I'll check all glow plug torque at 14 ft/lb in one go, so I got everything ready for a hot torque after I do glow plugs tonight ("unloaded" the torque wrenches) and finally installed the RiffRaff AIH delete plug. My cell phone's alarm went off to get the kids ready for school, so hit the snooze and got everything put up. Now for a nap, then buy 2 Motorcraft GP and check back on here before going back at it tonight.
I also checked the turbo for play in all directions, was nicely solid and spun smooth, no wheel damage. Up pipes and well basically everything exhaust under hood had zero signs of soot/leaks with inspection mirror.
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2001 Excursion 7.3 - stalls randomly, sometimes will not start. After the IPR was replaced it was rough for about 4 miles (I thought maybe air in the system), next 40 miles was flawless with 3 stops and restarts. Then it sat for a few hours and I went to leave again and the problem was off and on again for another 5 mile drive. Now it won't start in the driveway. It will start if I disconnect the ICP but the idle is still a little rough.
I replaced the normal culprits after a lot of searching on here:
CPS - replaced with autozone part, thought maybe it was bad new so went to ford and replaced with official part from the dealer
ICP - had oil in the plug and it would idle better removed so I replaced the plug and as much wire as I could - soldered, heat shrunk, good connections - both the pigtail and sensor came from Ford dealer
IPR - replaced with part from the Ford Dealer (FYI - 1 1/8" 1/2" drive craftsman deep socket from sears fit in the ratchet and on the part).
Grounds - found somewhere that the ground on the firewall for the windshield wipers can interfere with the CPS so I pulled it, clean the connections and made sure it was tight and secure.
No check engine light now - I received a few through the process, but did not clear them and there are no codes at this time (self cleared on the 40 mile drive)
I'm thinking it may be some electrical issue/short or a fuel issue at this point, bowl is full and the filter is fairly new (few thousand miles). I haven't done the Hutch mod, but have over 1/2 a tank.
I'm trying to get this going as quick as I can so I don't want to waste too much time, but I also don't want to miss a critical troubleshooting step to take.
Below are my thoughts on the next steps.
Research and test fuel pressure
Tow it somewhere to test each injector - I only have Torque pro to read codes and engine status
If fuel delivery checks out ok, start testing wire by wire on all of the above parts.
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My 7.3 will cough randomly on the interstate not towing or anything. It has a new turbo and filters...
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I have a 2003 mercury mountaineer 4.6L AWD. The other day it died at the grocery store and now won't start. All it has is the check charging system warning light on. Changed Alternator, battery and starter already and still nothing. It does start sometimes but i need to give it gas to keep it running.
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When driving my truck it coughs randomly not towing or anything going about 70 mph drops rps slightly and goes right back. It has 212000 miles new turbo and filters...
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Ok, so my 2002 f250 died on me last Tuesday out of the blue, pulled it home and found fuse 23 I think ECU power was blown. I removed my Hydra, and put a new fuse in it and all seemed well, then Friday evening on my way to dinner was driving along and truck shuts off like someone turned the key off. I replace the Crank sensor, even though I had put a new one in after the first time it died, which was last Tuesday, still would not start.
Pulled it home, went out Saturday morning to look at it and hit the key and it fired right off. At this point I don't really know where to look, I wiggled every wire I could find while it was running Saturday and no change, but it does seem to have a miss in it while it is idling...... I am not sure where to start looking....
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My engine suddenly stops while driving. There is no warning or loss of power, it just stops randomly after running fine for a while. After some time (might be minutes or hours) the engine turns on and runs fine.
I have no clue what it might be, I believe it might be an electrical problem affecting the diesel pump. The pump has a pair of cables coming in to a white plug at the pump's back, I disconnected them but the engine still runs.
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my 2000 f350 7.3 is acting strange lately. Its got 252k and is all stock other than exhaust,intake,ww2. It smokes white every random once in a while for some reason. At start up it wont though. If i get on it every once in a while it will smoke white then go to back to black. Im not consuming coolant, and the oil looks fine, no residue on the oil cap and its not puffing out the oil cap either. Other than that its running great just dont know why it goes white every so often.
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The engine in my truck sometimes cuts out seems to be at idle. Takes a lot of cranking together going. Might be related but the electric fuel pump seems to run every time I turn the key on and if i sit with key off and the engine not going. I hear the pump come on again. No external leaks can be seen.
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The red battery light on my 2003 gx470 with 106k miles came on while starting the truck up today. I had the alternator tested by my mechanic and it was outputting 13.0v -13.1v which was low but not causing any loss of power. The battery on two years old and tested out fine. Nothing was flickering, no loss of electrical components, etc. It's the original alternator and I'm going on a 1000 mile round trip vacation this weekend for 10 days I so decided to swap out the alternator since if it was "going" I didn't want it going 500 miles from home. My mechanic does the swap and starts the truck up with no issues and no red light on. Lets it run for 15 minutes and turns off the truck. 20 minutes later they start the truck up to switch lifts so they could balance and rotate the tires and boom the light goes on again? Turns it off and on a few times...light stays on. After testing everything out My mechanic decides it must be a bad alternator or the regulator inside the alternator and gets a different one from a different manufacturer, a Duralast this time from AutoZone. Installs it and the red light comes on immediately. The alternator is putting out 14v.
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As would be expected things deteriorate on a 16-year-old truck. My alarm has, on a few occasions, decided to annoy anyone around by activating for no apparent reason. This has happened in various conditions (in the parking lot, in the driveway, right after I've driven it, or sitting half the night). I chalked it up to aging circuitry.
Now I've picked up something new. Over the last few weeks my truck may or may not arm. It seems to be a flip of the coin. I'll drive to the store and I push the button on my remote and the truck goes "beep"..."beep". 10 minutes later I drive home, park the truck, push the remote, and the truck goes "beep"...and that's it. My alarm light is blinking two quick flashes when this happens.
Since this has started my truck has begun randomly having a delayed start. I'll disarm the truck, turn the key, and nothing happens for about 1 second or so (seems longer) then the truck starts normally.
Both of these issues started pretty close to the same time. I would normally go straight for a starter issue but I don't know if these might be related. I'm the second owner so have absolutely no idea about the Ford anti-theft system, how it's connected, or what the blinking lights mean.
I'm considering disconnecting the anti-theft system to see if that makes a difference but, as stated, how it's connected, what I might disable, or how it works. Was there any documentation published on it?
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I have a mostly stock '02 F-250.
The other day I parked the truck and as I was walking away I could hear what sounded like the 4x4 clicking on and off. I wasn't sure. I figured I would continue to run the truck to get more symptoms and come up with a diagnosis.
Later, backing out of the driveway, I heard what sounded like a buzzing/grinding noise, like something was trying to engage. It quickly went away.
The next day, the 4x4 light came on as I merged onto the interstate. I pulled over, tried switching the ESOF switch to get it to turn off. I never heard 4x4 engage or "felt" it. Re-starting the truck got the light to turn off. It hasn't been on since.
Today the truck made more buzzing/grinding noises. When I tried turning on 4 high with the ESOF switch I got no response. It went into 4 low and the light came on.
I re-started the truck. Tried putting it into 4 high again and the light came on. When I put it into 4 low the light quit and wouldn't come back on.
I run with my hubs unlocked and they were unlocked at the time, FYI. Also, I have air coming out of the vents, so no vacuum issues. I actually disconnected the 4x4 vacuum lines because I don't use the automatic locking future anyways.
I did do some work with my truck and boat during the flood in Louisiana and I took her through really sketchy stuff. My guess is that the ESOF motor is shot, most likely from being submerged.
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I am at a loss on what this could be. For the past 8 - 9 months my truck will randomly miss and if I am going slow enough it will cause the engine to quit but only when it is raining. I sometimes get a service light when it happens but as soon as i turn the key off and back on it goes away. My truck runs perfect otherwise and even when it rains except when it randomly does what I just explained.
This started when I replaced my passenger side valve cover gasket and I also took out my "brain box" (don't remember what it's called) and put it back in (didn't replace it). I did have the up-pipe replaced as well around the same time and put in EGT, boost and trans temp gauges. That's about the only things engine compartment wise that's been done.
I did just take it to a shop to put on a scanner and after his testing it did spit out 1 code. It was the cam position sensor. Can this sensor cause what I have explained? Like I said, this only happens when it rains. Doesn't matter if it's poring or barely sprinkling.
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I have a 2001 Excursion 7.3 Diesel that is having a starting issue. Have replaced the batteries, has new glow plugs, common failing cam position sensor replaced once already. It runs great when it starts, no codes. It will crank, but not turn over at random times. Will do this for 3 or 4 tries...charge the batteries, go back later to start and it will on the second try. Turn it off, try again..and back to cranking, but not starting. Not fun having to worry about being stranded somewhere. Absolutely desperate at this point.
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So I just bought a E99 f350 lariat. I wrecked the truck on the test drive and felt like the right this to do was to buy it. Finally have everything fixed and replaced on the truck and have run into other issues now.
While flushing the coolant system I started noticing that the starter was engaging randomly. After doing some research I found out it could be the GEM under the dash. Looked under the dash and I could here a sizzling sound and seen "smoke" /water vapor something coming off the GEM. And there is water coming through from the window/cab lights.
So. All the post I seen where from like 6 - 10 years ago. Where is the best place to buy a GEM? Will having the window replaced take care of the leaking issues on the window? What's the best after market cab lights? Cause I think they are leaking too.
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I have stock 02 F350 7.3 with 74,000 miles ... Today i looked down and noticed my RPM gauge sitting there at 0 ... It was working just fine yesterday. I figured before i go digging around looking for the issue id see what is causing it not to read ..
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