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Ford Truck Club Forum > FORD F-100 | F-150 SERIES > 1992-1996 Ford F150



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  #1  
Old August 14th, 2012, 01:50 PM
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Default 1994 F150 inline 6 weak charging system

Replaced battery, alternator (under Autozone warranty), and heavy wire connector (assembled by a professional). Charging system still weak at idle, under A/C load. Lights also affect it, but not nearly as much as A/C. Problem just started last week. Old alternator tests good on the bench at Autozone after failing an on board test (bad voltage regulator). New alternator fails the same on board test for the same reason. Have had it suggested that I upgrade to a 3G alternator. Need good instructions for re-wiring, if that is the best path forward.

Thanks,
George
  #2  
Old August 14th, 2012, 01:59 PM
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You already have a 3G, but there is a more powerful 3G (130amp vs. your 95 AMP) available. When you say weak charging system, what do you mean? Use a multimeter to check your voltage and post your results. What do you mean by wire connector?


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  #3  
Old August 17th, 2012, 11:24 AM
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I have a 75 amp alternator stock. Weak - my in dash meter normally runs vertical, or just to the right of verticle, toward the 18v side. Whenever that meter runs to the left of center, historically, my charging system is defective. That is happening at idle, sometimes, and only under the conditions of a full load (lights and A/C on). Sometimes, it now starts out low, and as I rev the engine, it moves to the center. I changed out both connectors on the alternator, a d shaped connector that has the voltage meter green / red lead, and the power connector, a larger rectangular connector. I had a profefssional make the connections. I do not want a fire hazard. That seemed to help the situation a lot, but it is still going low, just not as often. Low - when my voltage meter on the truck moves toward the lower voltage, an independent meter reads 13.06 volts across the battery. When the in dash meter is centered, the independent reading across the battery is at least 13.5 volts. Here is the thing. Autozone runs their test equipment on my charging system, and it gives them a voltage regulator fail code at idle, under full load on the old alternator, and on a new one. Those same alternators will pass Autozone's bench test with flying colors. I am about to drive this truck 1000 miles to a new job. I cannot afford to kill a battery in the middle of nowhere. I do not think that will actually happen, but my in dash voltmeter has NEVER behaved this way without a REAL problem with the charging system. What I cannot figure out is, what has changed in the charging system to produce this behavior, which is new. Could other wiring in the system, that I have not changed be so old that the resistance is just increased after so much exposure in Texas heat? I am just confused.

Last edited by davigf; August 17th, 2012 at 11:34 AM. Reason: add information
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Old August 17th, 2012, 11:34 AM
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By the way, I understand exactly what I need to do to change to a 130 amp alternator. RJM Injection Technology has some nice wiring kits to make the necessary changes. One problem, for my truck, it does NOT appear that the 130 amp alternator would really fit. The mounting hole spacing does not appear to be close. The mount bracket has an extra lower mounting hole, threaded and all, and it takes the bolt just fine. But, if you look at the 130 amp alternator, its mounts are 180 degrees apart. The mounts on my 75 amp alternator are not, and the offset that appears to be needed to accommodate the 130 amp alternator is not nearly enough on the bracket. This is a secondary issue at this point. I do not plan to make the change at this time. I am fearful that whatever is dragging down the 75 amp alternator (sometimes) will have a similar affect on the 130 amp alternator. Another question, what minimum amperage should I measure at the battery under a full load (ac and lights, at idle)?
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Old November 5th, 2012, 10:29 PM
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Was this ever resolved? I have the same problem in my 87. All stock.
  #6  
Old November 6th, 2012, 09:25 AM
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im only throwing this out there, but how old is your battery? whats the CCA of it?

a few years back i had a battery that wasnt taking a charge. ended up frying the alternator, new alternator and battery, problem solved

Aaron

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Last edited by ASwaff400; November 6th, 2012 at 09:31 AM.
  #7  
Old November 6th, 2012, 01:50 PM
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do what Booba said
do a voltage check

also most parts stores & WalMart will do a free charging system check


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