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OK... Here's the scenario:
Last weekend the battery light comes on. I check the alternator, it's not charging. I, one at a time, replace the brushes, the voltage regulator, then have the whole thing rebuilt, each time expecting to have the problem solved. But no. And I know what you're all thinking: mega fuse. Right? Well after finally hearing of this mystery part throught my brother-in-law (he's a long time CEGer) I locate it and sure enought, it's blown. Toast. So I replace it, feeling a bit saddened knowing it was probably the cause of all the problems. BUT! Here's the best part- IT'S STILL NOT CHARGING! What the #@*%!?
So what do you think? Is there another "secret" fuse in-line somewhere? Why would the mega fuse blow in the first place? Oh, and by the way, the mega fuse I put on is at this point still intact.
Any help?

95 Zetec LX
170K
Manual Trans
Old School Rockford Fosgate in the trunk

Have you actually had the alternator bench tested after you rebuilt it? If you haven't, start there. If so, start checking your wiring. I've had a few that actually melted the wiring when the mega fuse blew.

They tested it when they finished the rebuild, and it was fine. I have not had it off since I replaced the mega fuse. I might try that... As for wiring, what I can see is ok, but I haven't gotten into any of the sheilded wiring harnesses. I guess I've been a little burned out on working on it after all the times I've had it apart in the last week.

Let me have you clarify something..


You say it still isn't charging... by not charging, you mean that the battery light is illuminated, still.. or that you actually checked voltage across the battery while the engine is running, and you are staying at ~12V?


An illuminated light may just be the dummy wire that runs to the light in the guage cluster..

Just throwing some things out there...

Ray

Throughout the whole thing the battery light was on until I replaced the mega fuse. Then it went out. However, this not being the first time I have probed for electrical problems on a car, I was not satisfied, so I put a voltmeter accross the terminals. It showed 12v until I put the car under a load, at which point the voltage began to drop like a lead weight.

Thanks for helping me clarify.

I would check the wiring between the battery ground and alternator ground... or the battery positive to megafuse...

with a verified benchtest on the alt and a light that is off, but NO charge, I would think the wiring is ENOUGH to allow the light to go off, but not enough to carry a charge across it..


Helifino..

Ray

thanks for the reply. I had the dealer check the car, they say the alt is bad. I'm taking it back to the rebuild shop today to see what they say. Who knows...