Generators & Regulators Ford Explorer Sport Trac I

IDENTIFICATION

VIN CODE IDENTIFICATION

DESCRIPTION

System consists of generator, regulator, battery, fuses and associated wiring. Generators have an integral voltage regulator. Voltage regulator incorporates temperature compensation circuitry, so battery charging voltage is maintained at the optimum level. Charge rate is 13-15 volts.

Warning indicator should illuminate with key on, engine off. Warning indicator should not illuminate with ignition off, or with engine running.

BELT TENSION

Vehicles are equipped with automatic drive belt tensioner. Drive belt does not require adjustment. Inspect condition and tension of generator drive belt prior to performing any on-vehicle charging system tests. Replace belt and/or repair tensioner mechanism if necessary.

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

Ensure battery posts and cables are clean and tight. Inspect drive belt. Ensure connections at generator, regulator and engine ground are clean and tight. Inspect fusible links. Inspect central junction box fuse No. 15 (7.5-amp). Check all connections for looseness or corrosion. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

BATTERY TEST WITH DIGITAL BATTERY ANALYZER

Connect digital battery analyzer to battery and follow on screen instructions. If battery test good, return to service. If battery does not test good, replace battery.

BATTERY DRAIN TEST

Note. Amperage draw will vary from vehicle to vehicle depending on equipment package. Compare to a comparable vehicle for reference. No production vehicle should have more than a 50 mA (0.050 amp) draw.

1. Ensure junction box/fuse panels are accessible without turning on interior and hood lights. Drive vehicle over 30 MPH for at least 5 minutes. Park vehicle and allow to sit with ignition off for at least 40 minutes to allow electronic modules to power down. Go to next step.
2. Connect a fused jumper wire between negative battery cable and negative battery post. Disconnect negative battery cable from negative battery post, without breaking the jumper wire connection to prevent modules from resetting. Go to next step. NOTE: It is very important that continuity is not broken between negative battery post and negative battery cable when disconnecting battery cable or connecting ammeter. If continuity is broken, go to step 1 .
3. Ensure ammeter is set to read milliamps with at least a 10 amp capability. Connect ammeter between negative battery cable and negative battery post. Remove fused jumper wire. Go to next step.
4. If excessive current draw is present (50 mA or more), pull fuses from battery/central junction box one at a time and note any current drop when each fuse is removed. DO NOT reinstall fuses until test is complete. Go to next step.
5. Check wiring diagrams for any circuits that run from battery without passing through battery/central junction box. Disconnect these circuits if current draw still exists. Repair appropriate circuits as necessary. See POWER DISTRIBUTION in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

ELECTRONIC DRAINS WHICH SHUT OFF WHEN BATTERY CABLE IS DISCONNECTED

1. Perform battery drain test. See «BATTERY DRAIN TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__battery-drain-test) . Ensure all doors are closed and accessories are off. Without starting engine, turn ignition switch to RUN position for a moment, and then turn ignition switch to LOCK position. Wait a few minutes for illuminated entry lamps to turn off (if equipped).
2. Connect ammeter between negative battery cable and negative battery post. Disconnect negative battery cable from negative battery post, without breaking the ammeter connection to prevent modules from resetting. Read amperage draw.
3. Amperage draw should be less than 50 milliamps. If current draw exceeds 50 milliamps, remove fuses from battery/central junction box one at a time to locate problem circuit. Repair appropriate circuits as necessary. See POWER DISTRIBUTION in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

GENERATOR LOAD TEST

1. Ensure drive belt is in good condition. Replace belt as necessary. If belt is okay, connect charging system load tester in accordance with manufacturer's instructions. Start and run engine at 2000 RPM, and apply load until generator output levels off. Generator amperage should be at least 58 amps with engine at 2000 RPM. Go to next step.
2. Turn A/C system on. Turn blower speed to high. Turn headlights on to high beams. Voltage should increase a minimum of .5 volts. If voltage is as specified, system is operating properly at this time. If voltage is not as specified, perform «GENERATOR NO-LOAD TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__generator-no-load-test) .

GENERATOR NO-LOAD TEST

Connect a voltmeter positive lead to B+ terminal on generator and negative lead to ground. Start and run engine at 2000 RPM, with all accessories off. Read voltmeter when voltage stabilizes. Voltage should be 13-15 volts. If voltage is not as specified, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

SYSTEM TESTS

Note. For proper diagnostics, see VIN CODE IDENTIFICATION table.

SYMPTOM INDEX

TEST A: BATTERY IS DISCHARGED OR VOLTAGE IS LOW

Note. Failure to fully charge battery before retesting may cause false readings.

1. Check The Battery Condition Test battery condition. See «BATTERY TEST WITH DIGITAL BATTERY ANALYZER»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__battery-test-with-digital-battery-analyzer) under ON-VEHICLE TESTING. If battery is okay, go to next step. If battery is not okay, replace battery.
2. Check The Generator Output Perform generator load and no-load tests. See «GENERATOR LOAD TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__generator-load-test) and «GENERATOR NO-LOAD TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__generator-no-load-test) under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator is not okay, perform «TEST B: WARNING INDICATOR IS ON WITH ENGINE RUNNING, SYSTEM IS NOT CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators) .
3. Check For Current Drains Perform «BATTERY DRAIN TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__battery-drain-test) under ON-VEHICLE TESTING. If no excessive current draw was not found, go to next step. If any excessive current draw was found, repair as necessary.
4. Check For Current Drains Which Shut Off When The Battery Is Disconnected Perform «ELECTRONIC DRAINS WHICH SHUT OFF WHEN BATTERY CABLE IS DISCONNECTED»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__electronic-drains-which-shut-off-when) under ON-VEHICLE TESTING. If there are any current drains that shut off when the battery is disconnected, repair as necessary. If no drains were found, perform «TEST B: WARNING INDICATOR IS ON WITH ENGINE RUNNING, SYSTEM IS NOT CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators) .

Scheme 1

Scheme 2

1. Check Generator B+ Circuit (Black/Orange Wire) Measure voltage between ground and generator terminal B+ (Yellow/White wire). (Scheme 1) If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between generator and battery. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators).
2. Check Generator "A" Circuit (Yellow/White) Turn ignition switch to LOCK position. Disconnect generator 3-pin harness connector. Measure voltage between ground and generator harness connector terminal No. 1 (Yellow/White wire). (Scheme 2) If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between generator and battery. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators).
3. Check "I" Circuit (Light Green/Red Wire) For An Open Start engine and let idle. Measure voltage between ground and generator harness connector terminal No. 3 (Light Green/Red wire). (Scheme 2) If battery voltage is present, go to next step. If battery voltage is not present, repair Light Green/Red wire between generator and instrument cluster.
4. Check For Voltage Drop In B+ Circuit (Black/Orange) With the engine at 2000 RPM, measure voltage between positive battery terminal and generator terminal B+ (Black/Orange wire). (Scheme 1) If voltage is less than 0.5 volt, replace generator. If voltage is 0.5 volt or more, repair high resistance in Black/Orange wire between generator and battery.

TEST C: SYSTEM OVERCHARGES, BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS

1. Check For Voltage Drop In "A" Circuit (Yellow/White Wire) Disconnect generator 3-pin harness connector. Turn ignition switch to RUN position. Measure voltage between positive battery terminal and generator harness connector terminal No. 1 (Yellow/White wire). (Scheme 2) If voltage is less than 0.5 volt, go to next step. If voltage is 0.5 volt or more, repair high resistance in Yellow/White wire between generator and fusible link "C". See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators).
2. Check Generator And Battery Ground Connections Turn ignition switch to LOCK position. Inspect ground connections between voltage regulator, generator and engine, and between battery and engine. If problem exists, repair connections as necessary. If all connections are clean and tight, replace generator.

TEST D: WARNING INDICATOR IS ON WITH ENGINE RUNNING, SYSTEM IS CHARGING

1. Check "I" Circuit (Light Green/Red Wire) For A Short To Ground Disconnect generator 3-pin harness connector. Turn ignition switch to RUN position. Check warning indicator. If warning indicator illuminates, repair short to ground in Light Green/Red wire between generator and instrument cluster. If warning indicator does not illuminate, replace generator.

TEST E: WARNING INDICATOR IS OFF WITH IGNITION SWITCH ON & ENGINE OFF

1. Check The Charging System Warning Indicator Lamp Disconnect generator 3-pin harness connector. Connect a fused (15-amp) jumper wire between ground and generator harness connector terminal No. 3 (Light Green/Red wire). (Scheme 2) Turn ignition switch to RUN position. If warning indicator illuminates, replace generator. If warning indicator does not illuminate, repair warning indicator problem as necessary. See appropriate ANALOG INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.

TEST F: WARNING INDICATOR FLICKERS OR IS INTERMITTENT

1. Check For Loose Connections Inspect all generator, battery, and power distribution connections for looseness, corrosion, loose or bent terminals, or loose eyelets. If problem does not exist, go to next step. If problem exists, repair as necessary.
2. Check Fuses Start engine and let idle. Inspect central junction box fuse No. 15 (7.5-amp) for looseness. Wiggling fuse and note warning indicator operation. If warning indicator does not flicker, go to next step. If warning indicator flickers, repair loose fuse connections.
3. Check "A" Circuit (Yellow/White Wire) Connections Turn ignition switch to LOCK position. Connect a fused jumper wire between positive battery terminal and generator harness connector terminal No. 1 (Yellow/White wire). (Scheme 2) Start engine and let idle. Note warning indicator operation. If warning indicator flickers, repair warning indicator problem as necessary. See appropriate ANALOG INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If warning indicator does not flicker, repair loose connection(s) in circuits.

TEST G: GENERATOR NOISY

1. Check For Accessory Drive Noise Turn ignition switch to LOCK position. Check accessory drive belt for damage and correct installation. Check mounting brackets and pulleys for looseness and damage. If problem does not exist, go to next step. If problem exists, repair as necessary.
2. Check Generator Mounting Check generator installation. Ensure all fasteners are tight. If problem does not exist, go to next step. If problem exists, repair as necessary.
3. Check Generator For Electrical Noise Disconnect generator 3-pin harness connector. Start engine and let idle. Turn headlights on. Turn rear defogger on. Turn blower motor to high speed. If noise still exists, go to next step. If noise does not still exist, replace generator.
4. Check Generator For Mechanical Noise Turn ignition switch to LOCK position. Connect generator harness connector. Start engine and let idle. Turn all accessories off. Using a stethoscope, check generator for unusual mechanical noise. If generator is source of noise, replace generator. If generator is not source of noise, isolate noise and repair as necessary.

TEST H: RADIO INTERFERENCE

1. Verify Generator Is Source Of Radio Interference Start engine and let idle. Tune radio to station where interference is present. Turn ignition switch to LOCK position. Disconnect generator 3-pin harness connector. Start engine and let idle. If interference is still present, repair radio concern. If interference is not still present, replace generator.

REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Remove engine appearance cover bolts. Unclip air cleaner outlet tube wire harness. Disconnect crankcase ventilation tube. Loosen air cleaner outlet tube clamps. Remove air cleaner outlet tube. Rotate accessory drive belt tensioner counterclockwise. Remove accessory drive belt from generator pulley. Disconnect wiring harness to voltage regulator harness connector.
2. Remove terminal B+ cover. Remove terminal B+ nut. Disconnect terminal B+ electrical connector. Remove wiring harness-to-generator pin-type retainer. Remove generator stud bolts and nut. Remove generator. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/charging-system/#generators-regulators__torque-specifications) .

2002-03 GENERAL SPECIFICATIONS

2002-03 EXPLORER SPORT & SPORT TRAC GENERATOR SPECIFICATIONS

2004 EXPLORER SPORT TRAC GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

2002

For wiring diagrams, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2003

For wiring diagrams, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2004

For wiring diagrams, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• SYMPTOM INDEX
• BATTERY DRAIN TEST
• GENERATOR NO-LOAD TEST
• A
• C
• D
• E
• F
• G
• H
• BATTERY TEST WITH DIGITAL BATTERY ANALYZER
• GENERATOR LOAD TEST
• ELECTRONIC DRAINS WHICH SHUT OFF WHEN BATTERY CABLE IS DISCONNECTED
• TORQUE SPECIFICATIONS