Sounds like at least one if not both of your alternator brushes are worn down considerably. When they get worn quite a bit, the spring tension on them becomes less and therefore, they will start to float at higher rpm's due to the springs not able to hold them in good contact with the armature.
btw, my charge indicator light just started coming on at around 2500 rpm. I just had mine apart tonight and one of my brushes is very worn and floating. It looks like I need to get a voltage regulator because it got hot enough to melt it some where one of the springs are housed. The brushes are in the voltage regulator, found on the back of the alternator. Had to take the back off my alternator to get at the regulator.
That alt sure is in a tight spot in my 99/zetec. The haynes manual says it has to come out below by the right wheel along with having to remove the oil filter. Don't think so. Mine came out from under the hood right next to the strut tower. It sure is in one heck of a spot.
Ray
New Brunswick,CANADA
99 SE Sport ; T-Red ; 2-tone Gray Interior ;
Zetec ; ATX ; 885 fogs ; [ no ABS
]
65w 9005 ; 55w 9006 ; my headlight fix (aim beams separately)
