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7 altornater's in 6 months, Any Ideas why??

Discussion in 'Ford Trucks' started by Plowtoy, Jan 17, 2012.

  1. Plowtoy

    Plowtoy Senior Member
    Messages: 929

    So one of my subs has a 00 super-duty with a 7.3 and around 340k on it. Since June he has had 7 alternators replaced at a local garage. As of the last 2, I have tried to help him figure it out. 2 alternators ago he also replaced the batteries with new thinking maybe a dead short in one of them. They also wired a 12v constant to the "field/signal" input wire, since signal wasn't always there. The last alternator failed this past Saturday while we were out plowing. He brought it back to the same garage he's been going to and they replaced it again for free (btw, the last 3 were OE ford alternators). Since this past Sunday we cleaned the connections on the output of the alternator, and where they meet on the starter solenoid on the passenger inner fender. We also cleaned all the other connections on the starter solenoid (that is where the output goes to the battery, btw, truck doesn't have any problems starting). We also ran another output wire directly to the drivers side battery from the alternator on Sunday. As of today i haven't heard from him, but I want to be ready if it goes out again. Any ideas? Sorry for the long post
     
  2. coldcoffee

    coldcoffee Senior Member
    Messages: 776

    I've been dealing w/ a similar issue, but mine seem to be going about every 14-18 months, but mines a 6.0. See if he got a notice w/ the new unit that says something about checking a ground wire on the truck. Mine always comes w/ a notice, but I'm not sure which ground they are referring to. I'm taking mine back into a wiring specialist hopefully this week...I'll try to pick his brain & see what he thinks.
     
  3. iceyman

    iceyman 2000 Club Member
    Messages: 2,542

    After2 i would be pissed.
     
  4. Milwaukee

    Milwaukee 2000 Club Member
    Messages: 2,180

    It common issues on those in salt State.

    Wiring get rot and doesn't made good contact.

    I tape the live wire that for positive on alt. Don't use that one. Use 2 gauge cable from Alternator output to Battery post + plus 105 AMP fuse in middle cable. Factory harness are undersize and get REAL HOT. I witness red cable become yellow/white after running all electric. I believed they are 4 or 6 gauge.

    Then another ground cable from Battery post -- to Alternator's bolt.

    Make sure that both batteries on side are good. It can't be 1 weak and 1 best it will kill alternator and best battery died early.

    Get volt multi tester and do OHM on all connectors. That how I did on mine 2000 F350 7.3L.
     
    Last edited: Jan 17, 2012
  5. Plowtoy

    Plowtoy Senior Member
    Messages: 929

    Me too. He is at his wits end with this thing. He loves the truck but is too cheep to bring it to the dealer like I told him. There's probably a TSB out there somewhere for this issue
     
  6. RepoMan1968

    RepoMan1968 Senior Member
    Messages: 439




    after the second one I would have found a new garage.
    your telling me that the mechanic didnt bother to diagnose the problem and charged him 7 times for labor and 7 alts?

    something rotten in denmark dontcha think
     
    Last edited: Jan 17, 2012
  7. Plowtoy

    Plowtoy Senior Member
    Messages: 929

    No, they only charged him for the first one 6 months ago. The problem is the inconvenience of being with out the truck. He uses his truck all day every day so when its down, regardless of warranty, it costs him money. I do agree, he should have gone somewhere else, but he feels the warranty wouldn't apply if he took it to a different garage. After the last one, I think I stated that above, I told him to bring it right to the local ford dealer, but he choose to let the original garage "deal" with it.
     
  8. RepoMan1968

    RepoMan1968 Senior Member
    Messages: 439

    under the lemon law here , he qualifies for a new wheel after the 3rd alt.
     
  9. broncscott

    broncscott Senior Member
    Messages: 101

    Bad grounds cause alot of problems
     
  10. plowguy43

    plowguy43 PlowSite Fanatic
    Messages: 5,269


    Do what he said.
     
  11. RepoMan1968

    RepoMan1968 Senior Member
    Messages: 439

    Much too late for that , the man right well deserves a new wheel under the LemonLaw
     
  12. plowguy43

    plowguy43 PlowSite Fanatic
    Messages: 5,269

    Did I miss something somewhere saying he just bought this truck from a dealer?
     
  13. Milwaukee

    Milwaukee 2000 Club Member
    Messages: 2,180

    No it had 340K miles on 2000 superduty. It not fall in lemon law due age and mileage.
     
  14. plowguy43

    plowguy43 PlowSite Fanatic
    Messages: 5,269

    That's what I thought as well.
     
  15. RepoMan1968

    RepoMan1968 Senior Member
    Messages: 439

    here it goes for used as well as new
     
  16. MickiRig1

    MickiRig1 PlowSite Veteran
    Messages: 3,617

    I do believe he has wire harness issues. I due believe the alternators are internally regulated. So if they are getting 12 volts to them they should operate and put out. I have heard the lower one does have issues with salt and crud. But 7 replacements must mean there is harness problems. They need to strip all the covering off and look for bad wire or connections. Or just rewire the whole charging circuit with a good "Run" circuit connection.
    I see what my Head Mechanic, a 7.3 expert thinks, when I go back to work Monday.
    Ambulances are charging night mares for them.
     
  17. Plowtoy

    Plowtoy Senior Member
    Messages: 929

    Just an update: We've been out plowing several times and he has put on a few hundred miles since the OP. Since we have added the additional output directly to the battery and cleaned the connections on the starter relay, there have been no problems. I will keep you posted as the winter progresses. Thanks for all your input, Dave