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Originally posted by LilLowEK:
OKay thanks, but what is this "mega fuse" you speak of?
Is it a possible culprit to the problem??
If the light is on constantly, yes, it could be the problem.
Ray's how-to has a description of where and how to access it for the Duratec. I'm not sure if the location is the same for the Zetec. Also the voltage for it should be different for Zetec. It should be on the Megafuse (if it is in fact, the problem - sounded like Ray in this last sentence. Scarey!)
"Always do the cheap and easy ones first."
1996 V6 ATX 96K miles
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Okay, well the light isn't on all the time from what she tells me. W/ no load, I guess it went off.
I'll check some basics. Turn on the lights, see if it comes on, etc.
Take it to Auto zone and get it checked. If they say it's good, I'll check the tension of the belt, etc.
Thanks alot Tony. 
Btw, any more information you may have, or anyone, post it up please.
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The "mega-fuse" is a high value (150-175 A) fuse that is located in the cable line that goes from the alternator/generator to the battery.
Not sure where it is physically located on a Zetec, but it is very well hidden on the Duratech.
If the fuse opens, charging current from the alternator cannot reach the battery and will cause a constant BATT light.
Steve
98 Contour SE Sport 2.5 Duratec ATX The wifey's car
89 Taurus SHO - 246K miles
94 SHO ATX - 190K
1997 F-150 5.4L ATX - The Workhorse 150K.
ANY THREAD WITH "OMG" or "WTF" ETC IN THE TITLE WILL BE IGNORED!
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I did read something Ray was saying about floating brushes.
So, the regulator? What part is that? You can replace it w/ out removeing the alternator? Hmm
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Originally posted by LilLowEK:
I did read something Ray was saying about floating brushes.
So, the regulator? What part is that? You can replace it w/ out removeing the alternator? Hmm
...
Haynes has a good description of the regulator and brushes, how to remove it and put it back in (both regulator and brushes). I think regulator is $40 and brushes $8 from parts store.
"Always do the cheap and easy ones first."
1996 V6 ATX 96K miles
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So you guys think it may be the regulator and brushes? They can be bought at an autozone??
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Originally posted by LilLowEK:
So you guys think it may be the regulator and brushes? They can be bought at an autozone??
Could be reg and brushes. I read that if the inside of alt. is "scarred/gouged in", in won't do any good to change brushes. Unfortunately, that can only be determined by taking out the alt and looking at the inside. In the past when I changed alt. for my chevys, it was cheap ($70), so the thought of changing just the reg did not come to mind. For the Fords, I think, we are looking at $170 or so. But for the Duratec, the hassle of it just makes it worthwhile to just replace the whole thing. I tried this past weekend to access the reg. for the alt in my duratec (just to try but no go. (got my tiny hand and screwdriver in but not enough leverage to turn the screws for the reg.)
Yes, regualtor or brushes can be bought from Autozoen or advance.
"Always do the cheap and easy ones first."
1996 V6 ATX 96K miles
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As I stated in the PM to you, and others have stated:
The possible causes for YOUR scenario (light on, not all the time, under load more often than not), are:
Alternator starting to go out.
Serpentine belt slipping (not busted.. busted would be a no charge scenario)
That's it.
I wouldn't suspect the megafuse (it would be an all/nothing condition, like a broken belt) and I wouldn't suspect the bruses, yet. They normally float at upper rpms, not lower rpms with load.
My biggest culprit, so far, would be slipping serp. belt, however an alternator isn't out of the question, yet. (There are other parts to an alternator that CAN fail and be present at lower rpms, and brushes CAN float at lower rpms.. however unlikely it may be)
Ray
'99 CSVT - Silver #222/276
In a constant state of blow-off euphoria.
Originally posted by Kremitthefrog:
I like to wear dresses and use binoculars to watch grandmas across the street.
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Thanks Tony, and thanks Ray. So, if Autozone says the alternator is good, it's probably just a slipping belt? Thanks alot guys.
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