Battery not charging-new alternator - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 06-29-2015
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Battery not charging-new alternator

Hello,

I'm new to this site, so I hope I'm doing everything correctly. I have a 2003 ranger with a 2.3. I noticed that my battery light was on, and that my voltage gauge in the instrument panel was low. I replaced the battery a few months ago, so it is new...this problem just showed up in the last couple of weeks.

With the engine running at idle, that battery only showed about 11.7ish. I charged the battery and drove to the farm to "fix" the problem with a new alternator. However, after the replacement, I'm still having the same problem....not charging...still showing around 11.7 and light/gauge is still on and low. Is there a fuse that controls the alternator? Where is it located? Any other ideas and help would be much appreciated. I do not consider myself much of a mechanic and definitely not when it comes to electrical problems, but i can follow instructions. I have owned rangers my whole life, and know a lot about the issues that face them, but this is new to me.

Thanks,
Kyle
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Old 06-29-2015
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Yes, there should be 2 fuses in the engine compartment fuse box, a 60amp and 40amp I believe.
On some they added a Mega Fuse it would be just outside the fuse box with 2 larger wires connected, test both sides for battery voltage if only one has voltage fuse is blown

test alternator for voltage.
With key off the larger B+ terminal on the back of the alternator should have 12volts(battery voltage)
If not then fuse is blown

Start engine
test B+ terminal again, it should have 14.5volts to 15volts, if not new alternator is probably bad.

But turn off engine and key and remove 3 wire connector, center wire should have 12v(battery voltage), if not a different fuse is blown.

Turn on key, green wire should now have 12volts, thats the battery light power
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Old 06-30-2015
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Thanks, RonD. My landlord and I looked at the fuses last night...they seem okay. He got under the truck the check the alternator voltage while it was running...he said it was only putting out 1 volt! I'm taking the old and new back to the parts store today and getting them checked. However, I had a question regarding the 3 wire connector: After unplugging it last night to remove the alternator, I noticed that there are only two wires going to it?? One one each side, the middle does not have a wire. Looking at this a little closer, it does not seem to me like there was a broken wire. I pulled off some of the heat tape, and never found it? Plus, I would think it would be noticeable since the problem just started a couple weeks ago...I should be able to see a broken one if it was there. Did some of these just use the two wires?

Thanks
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Old 06-30-2015
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I just found a wiring diagram for 2003 Ranger 2.3l, sorry I can't link it here.

Yes it does show only 2 of the 3 wires on that connector, 3.0l and 4.0l will have jumper wire there.

But what is interesting is that they don't use fuses...............
Ford is using fusible links on your model, like they did in the '80's

A fusible link is a short colored wire that is a smaller gauge than the main wire, it's purpose is the same as a fuse but it will allow slightly higher amps before separating(blowing), this wire will heat up and separate without causing a fire.


The Yellow/white stripe wire on the 3 wire connector should have 12volts, key on or off
It is connected(spliced) to the Black/orange stripe that is connected to B+ on back of alternator, there is a brown color fusible link at that splice

3 wire connector-------Yellow wire----------(fusible link)-----Black wire

Check the B+ Black wire first, it should have battery voltage, key off or on, if no voltage the it's fusible link is blown and there would also be no voltage at the Yellow wire because of this.

Battery Junction box(fuse box)-----Red wire----(fusible link, Gray color)----Black/orange wire----(splice)-------Alternator B+


There is also Fuse #11 in the cab fuse box, it powers the battery light and/or Voltage gauge, but if battery light comes on with the key then that fuse is OK
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Old 06-30-2015
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Thanks for the info! We'll get that checked in the next couple days...busy tonight and tomorrow. It has to be one of the issues described above, as I got the old and new alternator tested, and they were both good. I'll keep you posted over the next couple days.
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Old 07-14-2015
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RonD,

Just wanted you to know that we found the problem...The yellow wire going to the plug had a bare spot in it, and it broke right in half! Thanks for all of the help. Saved me over $200 for a new alternator, and would have had difficulty finding the problem had you not shown me where to look for the fusible link. Thanks!
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Old 07-14-2015
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Good work finding that broken wire, hard to do.

Thanks for the update and fix info
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