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Battery Light Always On After Alternator Replacement - FIXED!

25K views 55 replies 7 participants last post by  cjfisher  
#1 ·
As usual, not covered in searched threads . . .

Batteries brand new 3 months, holding 12.6 after sitting.
Old alternator died. Replaced with Duralast.
Ford Gauge and Edge Insight CTS2 show charging at 13.6 - 13.8.

PCM was cleared.

Alternator tested by Autozone and shows good.

Batt light did not come on with the old alternator until it died.

Multimeter backs-up what the gauges say. Anyone?
 
#9 ·
Found this, but on a Ranger. Is that "wht/blk" wire something that should be internal?

201859
 
#11 ·
This page has a picture of the alternator system. It shows only the two wires, plus the black/orange power wire.

 
#13 ·
Are you sure that the alternator is charging the batteries?

The alternator gets it's exciter voltage from the wire from the light on the dash. Without this voltage the alternator will not begin to charge.

I went through this with another member either here or on TDS and he finally found a broken wire, but he was not charging and it was on a OBS truck so the diagram that I am posting here may not have the correct wire colors for a Super Duty but you may get the idea since the alternators are the same.
 

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#15 ·
Are you sure that the alternator is charging the batteries?

The alternator gets it's exciter voltage from the wire from the light on the dash. Without this voltage the alternator will not begin to charge.

I went through this with another member either here or on TDS and he finally found a broken wire, but he was not charging and it was on a OBS truck so the diagram that I am posting here may not have the correct wire colors for a Super Duty but you may get the idea since the alternators are the same.
Thanks for that. My 94 is sort of charging. Guage in dash not working battery light sometimes on. Been a nightmare to figure out

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#14 ·
Yes, it is charging the batteries, as per Autozone test, as well as my multimeter, and the CTS2 gauge.

Actually, going by memory, the wires are the same colors.
 
#16 ·
Well, I had noted that the alternator charging rate was fluctuating, and had gotten as high as 14.6v. I swapped it out at Autozone.

Damned idiot light is still on. I don't get it. Grrrrrr

Dash charging meter shows it dead center, and the CTS2 shows it charging 13.8. This is so annoying.
 
#21 ·
l ended up buying a whole new engine wire harness. So, that's not it.
 
#19 ·
Having the same trouble with my 94 doc, and I replaced all those. I'm thinking circuit board problem on the back of the gauges.

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#20 ·
How is it a simple alternator swap could do that?

It worked fine.

The alternator failed.

New alternator in and working. Light doesn't go out.

You'd think there is some code to be cleared, but . . .
 
#22 ·
How is it a simple alternator swap could do that?

It worked fine.

The alternator failed.

New alternator in and working. Light doesn't go out.

You'd think there is some code to be cleared, but . . .
Mine was fine before I pulled the engine. Same alternator went back in. When/if I figure it out I'll let you know

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#23 ·
Probably fried the resistor for the light.

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#24 ·
Have you tried grounding the wire that goes back to the light?

A resistor is fairly robust and it takes quite a bit to take one out, plus you would quite likely smell it if it did burn.

Since the light gets it's power from the ignition switch grounding the alternator side of it should turn it off and give you something else to look at.
 
#27 ·
Have you tried grounding the wire that goes back to the light?

A resistor is fairly robust and it takes quite a bit to take one out, plus you would quite likely smell it if it did burn.

Since the light gets it's power from the ignition switch grounding the alternator side of it should turn it off and give you something else to look at.
I just did. No good. The two sides must be equal for it to go off. I have to figure out why they are not.
 
#26 ·
Here's my thought . . . But what can be causing the voltage difference?
201974
 
#30 ·
Have you verified the output voltage to the wire going to the indicator light from the plug. Without that wire hooked up

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Both the plug side and the wire side say near-zero volts on the light green/red.

The autozone guy says it should have battery voltage on the light green / red wire.
 
#33 ·
I thought so, but the AutoZone guy said no. The wire was to provide the 12V so that the regulator "started". I cannot find anything that says either way.
 
#35 ·
The "A" wire has battery voltage. it is the "I" Wire that does not - nor does the alternator side where the I wire goes in. (Bottom red circle in the pic above.)