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Test F: Warning Indicator Flickers Or Operates Intermittently

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

  1. Check For Loose Connections

    Inspect all generator, power distribution and battery connections for looseness, corrosion, and loose or bent terminals. Are all connections clean and tight? If yes, go to next step. If no, repair as necessary. Test system for normal operation.

  2. Check Fuse Connections

    Start engine and let idle. Check smart junction box fuse No. 10 (10-amp) for looseness. Wiggling fuse and note warning indicator operation. Does the charging system warning indicator flicker? If yes, repair loose connection as necessary. Test system for normal operation. If no, go to next step.

  3. Check "A" Circuit (Yellow/White Wire) Connections

    Turn ignition off. Using a fused jumper wire (30-amp) connected to positive battery terminal, backprobe generator harness connector terminal No. 3 (Yellow/White wire). See Figure or Figure . Start engine and let idle. Note warning indicator operation. Does the charging system warning indicator flicker? If yes, for 2.3L engine, install a new generator. See GENERATOR  under REMOVAL & INSTALLATION. Test the system for normal operation. For 3.0L engine or 4.0L engine, go to next step. If no, repair loose connection(s) in the circuits. Test the system for normal operation.

  4. Inspect "S" Terminal

    Turn ignition off. Check generator 1-pin harness connector for damage, corrosion and looseness (White/Black wire). See Figure. Is the "S" terminal in satisfactory condition? If yes, go to next step. If problem exists, repair as necessary. Test system for normal operation.

  5. Check Generator Brushes

    Remove generator from vehicle. See GENERATOR  under REMOVAL & INSTALLATION. Measure resistance between voltage regulator "F" terminal screw on back of generator and generator 3-pin connector terminal No. 3, component side. See Figure and Fig 1 . Is the resistance less than 5 ohms? If yes, replace generator. If no, go to next step.

  6. Check For A Grounded Slip Ring

    Remove voltage regulator and brush holder. See VOLTAGE REGULATOR  under REMOVAL & INSTALLATION. Measure resistance between generator housing and each generator slip ring. See Fig 2. Is the resistance greater than 10,000 ohms? If yes, replace voltage regulator. If no, replace generator. See GENERATOR  under REMOVAL & INSTALLATION.
Fig 1: Exploded View Of Voltage Regulator & Brush Holder
G94J32143Courtesy of FORD MOTOR CO.
Fig 2: Checking For Grounded Generator Slip Ring
G99J02409Courtesy of FORD MOTOR CO.
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