Ford F-150 (2004-2008) :: Battery Light Came On - Alternator Goes Then Dash Go Black


Apr 5, 2011

Last night battery light came on. Drove 40 miles home with lights on. Today, it started so I headed out. About 10 miles of battery light on, gauge fluctuating mildly either side of middle, gauge suddenly drops dramatically. I turn around and head back. After a mile or so there's a terrible growling under the hood, sounded like it could be an alternator bearing. Just as I pull over, the noise stops but entire dash goes black. Popped hood, alternator spinning quietly and not hot. I drove back and it started stumbling and surging as the battery died and it finally quit almost all the way back.

I have battery on charger now. I assume the BCM is the regulator by feeding current back to the field? If so could the growling be the BCM feeding back a huge field and the rectifier bridge growing? And the BCM fuse blew because too much current to alternator field coils? Will it start with a charged battery with the BCM dead? I need it to run to get to the parts place. Which fuses do I need to check? Then, how do I check the alternator, wiring, BCM regulator to find original problem?

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Three days later, I have now installed a brand new alternator and battery, only to have the same symptoms pop up about one minute after start up. The warning lights are now accompanied by the passenger airbag light and all engine instruments needle sweep back and forth. Dash lights go dim and bright intermittently as RPM varies.

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