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Ford Focus Electrical and Lighting Problems

286 messages,  Last post on Nov 13, 2009 at 4:52 PM

You are in the Ford Focus Forum. Your Host is pf_flyer

What is this discussion about? Ford Focus SVT, Ford Focus, Lights, Electrical, Coupe, Hatchback, Sedan, Wagon


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#252 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [axelv] by pf_flyer HOST
Jul 30, 2009 (2:48 am)
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Replying to: axelv (Jul 29, 2009 6:07 pm)

I hate to seem like Mr. Obvious, but if the voltage is higher than what the book says it should be, it's NOT be regulated correctly. So just changing a wire isn't going to change that. The fact that the voltage at the battery has "stabilized" doesn't really seem to mean much since it has done so at a voltage higher than 14. "Less bad" doesn't mean OK.
 
Sounds like you're looking at replacing the voltage regulator to me.
#253 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [pf_flyer] by axelv
Jul 30, 2009 (4:40 am)
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Replying to: pf_flyer (Jul 30, 2009 2:48 am)

You certainly have a good point. 14.6 still appears a bit on the high side. But in automotive it's not all black or white, that's why I put so much time into describing the symptoms. I'm looking for the electrical guru who could maybe tell us what the problem is based on the symptoms. I don't think any more that the regulator is bad. After all, it regulates again. Ok, high, but it does. If it wouldn't, the voltage would increase with rpm. I'm thinking the reference voltage that the regulator uses has now stabilized to zero (because the cable came off completely?) and the regulator regulates to peak output. I'm guessing that before, the loose or corroded wire sent all kinds of wrong signals to the regulator, causing it to put out between 15 and 16.x volts. What doesn't make sense to me though, is why the engine is stalling now. I plan on soldering that wire back on and will check if that makes any differnece. I'd hate to replace the alternator/volt reg just because a wire is bad.
#254 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [axelv] by pf_flyer HOST
Jul 30, 2009 (12:44 pm)
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Replying to: axelv (Jul 30, 2009 4:40 am)

OK, then change the wire (the simplest/cheapest thing to do) and see where you are.
 
My gut is telling me it's the voltage regulator. If you're rationalizing the 14.6 as the regulator functioning again, just that it's getting bad input because of a bad wire, then the regulator was functioning all along.
 
Problem with that line of thought is that that's not how voltage regulators work. They are a device that puts out a steady set voltage, period. When they don't, they have, by definition, stopped working and need to be replaced.
 
My gut is also telling me that your now permanent waring lights are the result of damage done to electronics by the unregulated voltage you were experiencing. I hope I'm wrong.
#255 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [pf_flyer] by axelv
Jul 30, 2009 (1:34 pm)
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Replying to: pf_flyer (Jul 30, 2009 12:44 pm)

Quite honestly, I have no clue how voltage regulators work, I will have to do my homework first. An alternator is a reverse e-motor, so the faster it spins, the higher the output voltage (and I know that). So something has to be there to keep the voltage steady. I've seen up to 16.3V before, now I only see 14.6, steady, regardless of rpm. So something is regulating again, what it is I don't know. Anyway, I got my replacement pigtail 181 today, borrowed a soldering iron, and am ready to put that thing in. Will post my findings later.
#256 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [axelv] by mickeymouse2
Jul 30, 2009 (4:51 pm)
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Replying to: axelv (Jul 29, 2009 6:07 pm)

Guru here,
 
The loose/bad conection may have been the initial problem of the alternater over charging, Resistance in the system causes the regulator to put out too much. This can also be caused by dirty cable ends, poor grounding, ect. Modern cars have grounding issues due to the number of plastic components. Its important that all those little ground straps that the manufacturer put on there are still there. You also have to understand that you have a computer controled vehicle.
Sensors do not react well with too much voltage. A damaged sensor might have occured also. You might be lucky and just have to reset the PCM by disconecting the negative or use a scan tool to go through a relearn proceedure to get the vehicle to stop dieing. 14.6v is not too high of voltage, try testing it with the lights on also. If bat light still on, the PCM might be sensing a diod ripple from the alternater and turning your bat light on. Here is an example; Vehicle was overcharging like yours, problem was fixed. Bat light still on. PCM data showed charging voltage at 15.5v when in reality it was now 14.0v. Ya, PCM's can get damaged by too much voltage and then simply be reading it wrong. This is why all manufacturers do not recommend ever jump starting your vehicle, your sending a voltage spike through out the entire system.
 
Finish your repair and see what the end result is. Even go ahead and put that other used alt in if you want. Scanning the PCM with a scanner that shows data (like a snap on) may end up being what you have to do. Good luck with it.
#257 of 286
Re: Pemanent bat light, stalling at idle, erratic voltage. [mickeymouse2] by axelv
Jul 30, 2009 (6:44 pm)
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Replying to: mickeymouse2 (Jul 30, 2009 4:51 pm)

Thanks Guru, for your insights! I just finished the work on the Focus. See some pictures by clicking here. It was a pain getting that connector off. I think I broke the old connector completely and also the alternator side has suffered a bit. Getting the insulation off the wires on the pigtail behind the alt was a pain too. Then, doing the soldering in that small a space was not easy either! But it was ok. Worst was getting the insulation off. Triple checked to make sure the wire order was correct the way i soldered it on and plugged the new connector in. Took me about 3 hrs total. Needed a lighted dental mirror, a soldering iron, a sharp knife, some tweezers, and a beer. Before the work I checked again. Voltage was 14.2 this time and the battery light still on permanently. Idle was bad, stalling. After the work was done, the battery light was off, voltage stable at 14.7V. With everything on, it went down to 14.3V. I did a short test drive. No issues. The gauges didn't flicker any more. Will drive it to work tomorrow and post my findings. So far I'm happy, but I don't trust it completely yet. Thanks so far guys for all the messages I received. Stay tuned for updates. BTW, the pigtail costs $37.
#258 of 286
Still high and varying by pf_flyer HOST
Jul 31, 2009 (3:27 am)
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"Above 14 volts" means just that. With the voltage out of the regulator varying, I'd wager you're still going to need to replace it.
 
The whole idea of the regulator is to provide that rock steady voltage.
#259 of 286
Re: Still high and varying [pf_flyer] by axelv
Jul 31, 2009 (5:18 am)
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Replying to: pf_flyer (Jul 31, 2009 3:27 am)

So please tell me, what's the actual voltage it has to be at? And what's the tolerance it can move around in? And is that independent of system loading? Thanks for your help.
#260 of 286
VOLTAGE by oldfordmech
Jul 31, 2009 (11:13 am)
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14.2 IS THE IDEAL VOLTAGE TO HAVE AT THE BATTERY WITH THE ENG RUNNING AT APPROX 1,000 RPM WITH A GOOD LOAD, ( a/c,wipers and headlights on)
Are u still having problem w/red alt light still on after doing above test ?
#261 of 286
Re: VOLTAGE [oldfordmech] by axelv
Aug 02, 2009 (10:29 am)
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Replying to: oldfordmech (Jul 31, 2009 11:13 am)

14.2, that's good to know, thank you for the information! With everything off except the engine I now have 14.6...14.7, steady. When I add some load (high beam, music, full blower motor) it drops to 14.3, also steady. The battery light was off since the repair, I drove 35 miles since and everything is normal. No flickering, no idle problems, no stalling, steady blower motor, steady headlight output.
As a quick history of the problem again: first the red battery light (not the orange engine light) came on intermittently. When it was on, I was normally able to shut it off by pressing the clutch pedal completely (it's a manual) or by changing gears, which involves pressing the clutch, so I figured it's probably not rpm related. The the light came on more frequently so I looked in the manual what could be wrong and started reading the forums and measured the voltage (up to 16.3V varying constantly with engine on) and so on. Then eventually the instrument lighting started to flicker and the headlights and blower motor rpm started to vary, and also the rpm and speedometer gauges started to have a life of their own (zeroing, going to max, then back to normal, also all warning lights came on - probably the instrument cluster self-test or calibration, and there was a bell (like when you forget the headlights and pull the key)). Then I looked in my book and the forums also said replace voltage regulator/alternator when voltage is over 14. While starting to work around the alt, I noticed the corroded wire, which then came off completely (the red wire on the 3 pin connector on the back of the alt [blue and white cable were still ok] - see some links to pictures in my previous posts). Once the cable was off completely, the symptoms changed: battery light on constantly, voltage stable at 14.7V, but now it was also stalling when at idle rpm. Then I bought the pigtail #118 from Ford ($37) and did the repair. Car is running normally ever since. (knocking on wood 3 times). Note that I did not change the alternator, and did not change the voltage regulator! Here's the link to the pictures again: Pictures

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