5th alternator going on... I really need some help

[wildcatgoal]

Right but if the issue is a wire (or in-line connector), typically you can identify that wire with physical (manipulating the wiring), resistance, and/or wave testing, which I would hope the "engineer" did a full battery of. I suppose the "bad" alternators haven't been tested in another car... that would be telling. Bad grounds with high resistance (but enough to still "ground") can cause a world of hurt, too, but typically alts ground to the block and these days have a small ground or positive voltage sensor wire connected to them -- suppose if that wire is bad there could be trouble but you'd think in 5 alt replacement they'd pick up on that if it was an issue. One thing I wonder is if the battery negative wire has voltage sensor on it like Chevy's do - I've never looked. If ground wiring is not going through that or the sensor is bad... issues.

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[Dominator961]

Right but if the issue is a wire (or in-line connector), typically you can identify that wire with physical (manipulating the wiring), resistance, and/or wave testing, which I would hope the "engineer" did a full battery of. I suppose the "bad" alternators haven't been tested in another car... that would be telling. Bad grounds with high resistance (but enough to still "ground") can cause a world of hurt, too, but typically alts ground to the block and these days have a small ground or positive voltage sensor wire connected to them -- suppose if that wire is bad there could be trouble but you'd think in 5 alt replacement they'd pick up on that if it was an issue.

Right but if the issue is a wire (or in-line connector), typically you can identify that wire with physical (manipulating the wiring), resistance, and/or wave testing, which I would hope the "engineer" did a full battery of. I suppose the "bad" alternators haven't been tested in another car... that would be telling. Bad grounds with high resistance (but enough to still "ground") can cause a world of hurt, too, but typically alts ground to the block and these days have a small ground or positive voltage sensor wire connected to them -- suppose if that wire is bad there could be trouble but you'd think in 5 alt replacement they'd pick up on that if it was an issue. One thing I wonder is if the battery negative wire has voltage sensor on it like Chevy's do - I've never looked. If ground wiring is not going through that or the sensor is bad... issues.

Don’t count on it. Most of these techs are parts changers.
And yes the negative does have a sensor on it.

I can almost bet you, they didn’t disassemble or wiggle test the harness.

 

[honeybadger]

Out of curiosity, which harness has already been replaced?

Scott - which harness are you advocating to be replaced? The one that runs from the fuse box to the instrument cluster?

 

[wildcatgoal]

So as fate would have it, that South Main Auto guy I recommended just repaired a Chrysler that was having sense-alternator issues. A connector along the chain that included the sensor wire going to the ECU was corroded.

 

[Tank]

@altjx , Let me know if you need DTCs looked up.

 

[ugstang17]

At a quick glance of the wiring diagram, and understanding that the transmission has been out of the car indicating that the starter has also been removed and reinstalled, I would be one to suspect a problem in the wiring between the starter and the battery connection point. Wouldn't be the first time a wire got pinched and caused a problem like this on a car.

So don't assume your dealer knows the transmission has been removed. Make sure they are fully aware of that. First rule of thumb as I have said before in troubleshooting...if a problem arises after something has been changed, first go back and inspect and/or unchange the change to see if the problem subsides.

A technician is only as good as the information provided him. Don't assume that the history on the car is complete in the Ford database. More than once while troubleshooting CNC Lasers in the field I have chased my tail for hours (even after asking the maintenance people what they had done up to that point) only to have one later on pull me aside and say, "Oh btw such-n-such also swapped amplifiers", and then find the phasing on the amplifier has been swapped.

Good luck to you.

 

[altjx]

Out of curiosity, which harness has already been replaced?

Scott - which harness are you advocating to be replaced? The one that runs from the fuse box to the instrument cluster?

Not quite sure 100% off the top of my head. I can get this information shortly, however. I was just informed during that time that the alternator's wiring harness had been replaced.

@altjx , Let me know if you need DTCs looked up.

Will do.

Thanks so much for all of the feedback, guys. I'll try to get some of this information relayed over to the dealership. The regional manager at Ford HQ just literally told me that all they can/will do is just simply honor the warranty, over and over, even if it happens 300 times. I can't believe they won't go "ok wtf is going on with this car?" and look into it, and instead just continuously replace the same thing over and over.

At a quick glance of the wiring diagram, and understanding that the transmission has been out of the car indicating that the starter has also been removed and reinstalled, I would be one to suspect a problem in the wiring between the starter and the battery connection point. Wouldn't be the first time a wire got pinched and caused a problem like this on a car.

So don't assume your dealer knows the transmission has been removed. Make sure they are fully aware of that. First rule of thumb as I have said before in troubleshooting...if a problem arises after something has been changed, first go back and inspect and/or unchange the change to see if the problem subsides.

A technician is only as good as the information provided him. Don't assume that the history on the car is complete in the Ford database. More than once while troubleshooting CNC Lasers in the field I have chased my tail for hours (even after asking the maintenance people what they had done up to that point) only to have one later on pull me aside and say, "Oh btw such-n-such also swapped amplifiers", and then find the phasing on the amplifier has been swapped.

Good luck to you.

I agree. I gave them the full run down after going to them because I had just changed dealerships. I also arranged communications with the old and new dealership so that we wouldn't have to run through this whole phase of "what happened" all over again.

I appreciate the advice!

 

[sZedely]

Attached is a summary of the Louisiana Lemon Law. See if your situation qualifies for lemon law. From the bit iveI read, there is a certain procedure on how to go about this in your state. This could be your issue with getting Ford to approve the buy back.

 

[altjx]

Attached is a summary of the Louisiana Lemon Law. See if your situation qualifies for lemon law. From the bit iveI read, there is a certain procedure on how to go about this in your state. This could be your issue with getting Ford to approve the buy back.

Thanks. Unfortunately, I don't think I meet these qualifications and I'm assuming that's why Ford rejected my buyback claim twice. I have 54k miles on the car and it's just a little over 2 years old now. My alternator issues haven't started until about 45k-ish miles and about a year and a half into owning the car. The other million issues I've had have always been random and not repetitive.

 

[altjx]

Just wanted to report back and say that Ford replaced the PCM, alternator, battery, and battery harness. So far, I haven't had this issue return just yet. We'll see how things go throughout the next few weeks.

 

[MikeHTally]

All that has to be aggravating. My '89 F-150 had a healthy appetite for alternators, gas too . It got so I could change one in under 30 minutes. I always suspected it was the VERY short trips between service calls, running the air constantly. Often wipers and lights, too. The alternator was only 70 ah.

 

[dmann]

Concerning the lemon law, I think it's per state, but my viper was in the shop 46 days and they still didn't buy it back.
I do think the buy back is a couple things.
1. The severity of the issue
2. The length of time in the shop

 

[Texas_Muscle5.2]

Just wanted to report back and say that Ford replaced the PCM, alternator, battery, and battery harness. So far, I haven't had this issue return just yet. We'll see how things go throughout the next few weeks.

Hey bro I’m having the same issue, I’ve literally changed two wiring harnesses, alternators and battery’s, did the PCM change help at all? Look forward to your response.

 

[lunatect]

Hey bro I’m having the same issue, I’ve literally changed two wiring harnesses, alternators and battery’s, did the PCM change help at all? Look forward to your response.

Take it to Larry Downs (service) at Penske Ford in La Mesa. Great service guy!

 

[Texas_Muscle5.2]

Take it to Larry Downs (service) at Penske Ford in La Mesa. Great service guy!

Thanks bro I’ll reach out to him. My last resort was going to buy a new PCM.

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