Dead Alternator? Not quite sure, yet...

[tarterd]

Greetings,

Scanned the Forums, but didn't find a complaint quite like mine. So, here goes.

I have 1995 Duratec, MTX, about 90,000 miles. Around 2005/2006, I was getting the flickering battery light and after checking the amount of charge at the battery, decided to install a new alternator. Got a rebuilt model from Team Ford and spent about five hours putting it in. Even with the "new" rebuilt one, the flickering battery light returned.

Got a second rebuilt alternator from Team Ford, and the charge to the battery fluctuated again; flickering battery light returned. Sometimes the light never came on, sometimes it flickered a bit and then went off again for a while.

About three months ago during a winterizing checkup, measured the charge at the battery, and when revving the engine to near 4000+ RPM, charge averaged 13.6 - 14.4. But as the engine returned back down to idle, the charge dropped dramitically, nearly less than 12; then returned to a stable 13.6, sometimes 14.

Kept driving the car (had to) even though the charge bug wouldn't go away. A week ago, the battery light stayed on, telling me no charge was making it to the battery. Car died en route to work - took it to Ford. Took them a week to analyze the issue, but they did and said it was the alternator.

I'm trying to figure out, even after installing two different alternators, could my problem be a wiring issue? If so, what are the critical check points? I'm concerned the dealership analysis is their easy answer.

Can anyone advise me how or where to direct them in case the Ford shop missed the "cheap or easy?" I'm not so sure they checked every possibility.

Thanks in advance for any help.

BTW - I'm in Norway with this US spec car. A new alternator alone through the Norwegians would cost around $900. Ordering would take over two weeks. Labor costs are additional and they're no joke.

 

[Tony2005]

1) Check Fuse 5 to make sure it is in tight. Make sure there is no rust on the holder.

2) Check Foglamps (if your car is equipped with them) to make sure the connectors are not rusted. The alternator charge circuit runs through the foglamps to Fuse 5.

 

[tarterd]

Thanks Tony for the response. Will check the connection at fuse 5; under the dash and not under the hood. If nothing there, I guess it's back to ordering a third replacement alternator. Wish these things were more reliable.

Thanks again.

 

[SVTJON87]

Thanks Tony for the response. Will check the connection at fuse 5; under the dash and not under the hood. If nothing there, I guess it's back to ordering a third replacement alternator. Wish these things were more reliable.

Thanks again.

don't order a 3rd alternator just yet. something tells me that might not be the problem. after 2 new ones it doesn't seem likely to be bad again. but don't quote me on that, i really do not have enough experience with charging systems.

 

[Mac]

i had a similar problem with the flickering batt. light and replacing alternator... all i did was checked all my connections, checked to make sure all the wires were in decent shape going to and from the alt. to bat. and gnd. and then after about a full weeks worth of driving to and from work, the light stopped flickering all together...

now i may be wrong but it sounds almost like you never really gave the new alternator enough time to "settle in" so to speak.. i know you said you charged the battery or what not, but still the alternator need at LEAST a couple days to like i said "settle in"...

hope this helps...

-Mac

 

[amc49]

I gotta disagree with that one. I've put in a hundred alternators and if they didn't cure out immediately something wrong with them or the car. Of course the battery must be in good viable shape. People do not realize how a battery that seems to be good can actually produce what seems like alternator problems. Our shop tester can show a battery as good, but alternator as marginal low on volts, everything else will test good like regulator and diode pack. The problem then is battery not alternator 9 times out of ten.

 

[tarterd]

All,

Thanks for the insghtful suggestions. I can tell you, on each occassion, I have given the alternator plenty of time to "settle in" and have also installed a new battery once or twice. The need for charging was to generally stave off the battery dying on me completely when the alt wasn't giving it any juice.

I will admit, I have not checked every connection and wire, which is generally why I placed the post. I know this is the best place to get good sound advice on how to best hunt down this nagging problem. I wanted to direct the mechs based on what I learned here.

After ordering the new alternator, I do know this, I'm going to hold the Ford mechs' feet to the fire to once and for all resolve this issue. It may cost me, but, this issue needs to go away.

Thanks again to all who offered ideas.