Had 4 alternators including one from Ford, changed out battery, checked all wires and grounds still putting out over 15 volts. Had it into the Ford dealership 4 different times still can't find solution.
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Re: 2006 Ford Tarus Over Charging from Alternator
Could be a pinched wire that did not show up when new. May have worked thin over the years.... Though to locate at times..... Bulk head headers can be a culprit, any where a wire passes through or over metal parts. Check for corrosion near battery terminals and alternator as a corroded connector can be "seen" as a resistance to the alternator and it will output more amps to compensate.....
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The battery light only comes on when there is a problem with the alternator or the charging circuit. Check all the wires, fusable links and connections. Also a good alternator test will put a large load on the alternator and read the diode tree.
Check all the connections to be sure the wires are in good condition. Check the battery terminals and make sure they are making good contact. Make sure none of the pins on the alternator are not bent and are lining up with the connectors. Be sure none of the wires are pulled out of the connectors. Use a Volt meter to check the voltage at the alternator and at the battery. It should be between 13.5 and 15 volts. Also check the grounds to the engine. I hope this help you locate the problem.
Check the fuses there are 4 that you will need to inspect.In the engine juction fuse box its a 50 amp fuse (big ones).Then goe to the panel fuse box (under instrument panel) fuse 15 mini.Then inspect the battery connection this includes the alternator wire itself. If the fuses are good do a wiggle test on the wire and alternator remeber your alternator is internal vontage regulator equipt that means wiggle test the connections
Check battery connections for corossion. Also check battery to body ground, battery to motor ground, and motor to body ground strap for corossion. Sometimes they corrode under mounting bolt and cause bad ground.
CHECK ALTERNATOR VOLTAGE OUT PUT AT BATTERY USING A DIGITAL VOLTMETER.WITH ENGINE RUNNING IT SHOULD BE 13.5 TO 14.5 VOLTS.IF NOT YOU HAVE A BLOWN ALTERNATOR FUSE.OR DAMAGE WIRES TO ALTERNATOR.IF VOLTAGE IS OVER 15 VOLTS NEW ALTERNATOR HAS FAULTY VOLTAGE REGULATOR.