2000 charging issues

Ok, i have a 2000 Windstar SE that has developed a charging issue. This was a sudden issue that came with no warning.

I pulled hte alternator and had it tested at Autozone and they showed it produced only 11.? volts. This was before i was told be ford that this unit is hard if not impossible to test in this way. This seemed to be confirmed when every parts shop in town was missing the proper 3-prong connector. I installed a new alternator and still no charging.

I tested accross the + post on the alternator to a chassis ground and got anout 11.6 volts, same as accross the battery.

I was told by ford that the truck needs to be plugged into a computer in order to diagnose the problem.

What i need to know is:
1) Is there a fuse/fusible link or relay that controls the charging system?2) Is there a way to test the 3-prong lead that plugs into the alternator?
3) Does anyone have any idea where i should look next?

thank you all!

hello clerick. How many miles & what size motor? Put the battery on a charger overnight. Then verify voltage is up to at least 13. Did your radio presets disappear before all this happened?

Karl.

Karl

I did charge it and was able to get the battery up to 13ish. Drove it home on battery power at night which drained it down to where it is now just under 12. The radio presets appear to still be intact. The van had been idling while my wife was wainting for me to get off work.... when we came back outside the van was not running. thought it was gas, but turned out to be dead battery and no alternator output had stopped the engine not lack of gas.

Strange, I've always used the lose of radio presets as the sentinal for a shot battery. Be it your battery or a bad alt, I would have thought they'd disappear. . Somebody can bench test it, we just need more details! Again. What motor do you have and how many miles are on it?

Karl.

3.8 116K. I have pulled it and was told by every parts shop that they are unable to test it. Ford said they couldm but it had to be in the car so they could plug in and see how many volts the ECU was demanding from the alternator. without the imput from the vans ECU they have no way of knowing if the voltage output is a correct response for the ECU's commands.

What i was hoping to find was a way to test w/o having to pay Ford $100/hour.

Just an opinion but if the alternator can't charge the battery but a charger can then one should suspect the alternator or the link between the alternator and battery.

I would be thinking the same as you in that I would not want to pay $100 for Ford to test it. What is the cost of a rebuilt alternator? Or an alternator rebuild kit. Maybe that is the route to take. as it will give the same answer as Ford. And that is good alternator or bad alternator. but it will also give you a working alternator at the same time

I already picked up a new unit and installed it to check. No change in the charging, or lack there of. So after 2 alternators i still have a no charge condition. the kicker is that IF there is a fuse in the system other then in a fuse box i can't find it! None of my books mention a charging relay or fuse anywhere in the van. According to a service guy who was nice enough to talk for free, this is all controlled by the computer. He also admited that he had never seen a charging problem in the new cars that wasnt the alternator, but you cant test the alternator unless it's in the van and pay $$$. I hate to goto the parts place and have them get another alternator if this one isnt bad, plus i have to wait for 4 days to get the #@%#$% shipped again.

Did you check your fuses in the Junction Box/Engine Comartment Fuse Box located next to the battery? Check your grounds. Make sure the chassis and block have a good ground connection. Make sure you double check the battery terminal too. Green residue is never good. VM

Ditto. ... in particular, check fuse #20 in the battery box.

I always have AutoZone check the alternators that I buy from them before leaving the store .... found a bad "new one" once.

Thank you for the advice. i would have the unit tested, only problem with that is that none, NONE of the local shops can test this thing out of the van. I bring it in and they always need are missing the 3-prong connector that fits this alternator. From what Ford said this is because you need a control voltage coming from the ECU that these bench testers are incapable of simulating.

http://www.automotiveforums.com/vbulletin/showthread.php?t=279154&highlight=charging

This person had a problem very much like you are having.........

Here's an idea, cut off the three prong thing that goes into the alternator and bring it in with that thing hanging off it. Then they'll know your serious . . . You're talking about the clip with green/red black/white yellow right? If I don't get this jaloupy back together, I'll mail you mine.

Ok here is an update. Talked to a mechanic i know at the local dealership. He thinks, from experience, that it has to be the alternators.

I back probed the three terminals and here is what i found.
1) two of the pins report battery/system voltage one of which is a reporting wire to the ecu.
2) the third wire reports between 8 and 10 volts depending on the system voltage. i tested this by running jumpers from my other van and supplying 13.5+ volts. the chance in pin 3's voltage corrosponded with the change in battery voltage.

with that information my mechanic friend is even more convinced that the alternators are bad, though he admits that there can be some really dumb things involved with charging/electrical problems.

i returned the alternator and should have #3 by tomorrow. Wish me luck!

be sure to check wiswinds link, and dig out that fuse.

Karl

wiswinds link?

and which fuse?

N/M i got it.... though i dont think that it is applicable. and old Winnie without a computer controlled regulator.

Did you check fuse #20 ... per my post above? Right out of my electric diagram for '99's.

Yep that i did. All fuses are fine. not sure about the realays, but i dont see one in the wiring diagram. Since there are no other riveability issues and no other system failures that i can find, i have mostly ruled out fuses e.t.c.

Two things that i cant figure out are:
1) On the front of the alternator mounting bolt there is a little black box that fits onto the bolt and is secured to the alternator that way, but then it has only one wire that grounds to the front of the engine compartment. What is this?

2) coming out of the loom that holds the + wire that connects to the alternator is a 3" or so single pin connector. What is this?

thanks for all the help so far. I am slowly eliminating issues. The wife should be back w/ alternator #3 soon.

Success!!

after all this it turns out to be the replacement alternator. :banghead:

I appreciate the help and input, i can deffiantely say that i learned alot obout my Winnie (have only had it ofr 2 months). this was the first issue i have had to address.

What i learned:
1) The Haynes manual i have doesnt even come close to addressing the 1999 and newer W-Stars.

2)Occam's Razor: When multiple solutions are present, the simpleist is preferred. Make no more assumptions then are needed. In other words, why look for trouble with the hard stuff when it is usually the easy stuff in the first place.

Thank you all!