My '03 has been a fantastic truck. It has @140,000 miles on it. About 6 weeks ago I put a new battery in it for the summer. While driving today with the stereo rocking and A/C pumping, it started to stall in traffic. I pulled over and stopped. I then noticed that the voltmeter was slowly dropping. I turned off all accs and luckily made it back home. The new battery was OK, and not the culprit. It still has the factory alternator, so I figured it was overdue for a new one. I purchase a ''new'' (not rebuilt) alternator, and installed it w/o much drama. The truck fired up, and the voltmeter was in a ''normal'' position. However the battery charge lamp on the instrument panel remained lit. I checked my work, even removing and reinstalling the alternator. I have also checked the Alt Field fuse, and made sure that the alternators electrical connections were secure. I have NOT checked the ALT MEGA fuse, and am not sure how to. Could it be that my ''new'' alternator is bad? I don't have a voltmeter to test anything. I am frustrated and hope some of you Ford fans can lend some advice so that I can get back on the road. Thanks very much.

 

You can try using the volt range meter in the digital odometer to see what the truck thinks it is ( over / under )
Activating Test Mode

To enter the HEC Dealer test mode, depress and hold the instrument cluster SELECT/RESET button, turn the ignition switch to the RUN position, and then continue pressing the SELECT/RESET button (5 seconds) until tESt is displayed in the odometer. The SELECT/RESET button must be released within 3 seconds of the odometer tESt display to begin the dealer test mode.

Depress the SELECT/RESET button to advance through the following steps until dtc is displayed. Depressing the SELECT/RESET button will display any stored continuous DTCs before proceeding to the next step.

GAGE
Activates gauge sweep of all gauges, then displays present gauge values. Also carries out the checksum tests on ROM and EE. If the gauge sweep is inoperative, INSTALL a new instrument cluster.

All segments illuminated
lluminates all odometer segments. If any odometer segment is inoperative INSTALL a new instrument cluster.

bulb
lluminates all micro-controlled indicators and LEDs. Install a new indicator or LED as necessary.

r
eturns to normal operation of all micro-controlled indicators and LEDs and displays hexadecimal value for ROM level. (used when requesting assistance from the hotline). If alternating flashes for FAIL and ROM level are displayed, INSTALL a new instrument cluster.

EE
Displays the hexadecimal value for EE level (used when requesting assistance from hotline). If alternating flashes of FAIL and EE level are displayed replace instrument cluster.

dt
Displays hexadecimal coding of final manufacturing test date (used when requesting assistance from hotline).

dtc
Displays continuous DTC's in hexadecimal format. Pressing the SELECT/RESET button will display any DTCs stored before proceeding to the next step.

enG
Displays the English speed in MPH. Speedometer will indicate present speed within tolerances. Display will show 0 if input in not received. If input is invalid for one second or more, or if speed is 0.

m
Displays the metric speed data in kph. Speedometer will indicate present speed within tolerances. Display will show 0 if input in not received. If input is invalid for one second or more, or if speed is 0.

tAc
Displays the tachometer data received from the PCM via the SCP network within tolerances. Tachometer will indicate present RPM. Display will show 0 if input is no received, if input received is invalid for one second or more, or if engine RPM is 0.

FUEL
Displays the code (0-255) for the fuel sender input to the HEC. The fuel gauge will display a filtered fuel level value. This filter will keep the pointer from moving suddenly or erratically.
255 open send +/- 0
232 full stop +/- 0
215 Full mark +/- 10
178 3/4 mark +/- 8
138 1/2 mark +/- 7
93 1/4 mark +/- 5
41 E mark +/- 4
54 Low Fuel (0-59)
0-18 short (0-20 max)

OIL
Displays the code (0-250) for the oil pressure switch input to the HEC. Oil pressure gauge will indicate present oil pressure. Normal oil pressure (greater than 6psi) will display a value between 000 and 176. A low oil pressure or an inoperative engine oil pressure switch (less than 6 psi) will display a value greater than 176.

dEGC
Display of engine temperature in Degrees C input from cylinder head temperature sensor.
49 C "C" mark
60 C Normal band start
120 C Normal band end
-40 C No SCP message for 5 seconds

bAtt
Displays the code (0-255) for the battery voltage input to the HEC. Battery voltage gauge will indicate present battery voltage.
93-102 6.2-9.1 volts, low voltage
115-124 8.5-10.7 volts, Normal band start
215-225 15.8-18 volts, Norm band end
230-241 16.9-19.1 volts, high voltage

rhEo
Displays the present decimal rheostat dimming input, 0-255 (used when requesting assistance from the hotline)

rhi
not used

rhS
not used

rho
not used

Cr
Displays the current RUN/START sense input. Display will show -h for high input with the ignition switch in the START position and -L for low input with the ignition switch in the RUN position.

PA-PE7
not used

GAGE
Repeats the display cycle

Source: Helms 99 manual.

 

Thanks SSCULLY for your help. I performed the test and the batt input seems fine. I am wondering if the problem lies in the alternator harness, as the charge light remains on. I am going to remove the alternator a third time and have it tested in order to see if I got a bad one. Any other suggestions anyone? I will post up when the problem is corrected. Thanks again all.

 

It turns out that my ''brand new in box'' alternator was defective. After securing a replacement, I'm back on the road. The Superbeast lives on!