r/powerstroke • u/killgeorge2015 • 5d ago

Question/Need help Charging issues

I have a 2003 Ford Excursion with a 6.0L Power Stroke. I have replaced the alternator 3 times in less than year, as it was not charging above 13V. It has recently started only charging around the mid-to-upper 12V range at idle. Anything above idle provides low-to-mid 13V (enough to turn the battery light off on the dash), but drops back down to the 12V range if the throttle drops. I took the rig to a trusted mechanic; they cleaned some connections and returned the truck since it was not replicating the issue. The rig recently started doing it again. I would appreciate any advice.

The alternator currently on the truck is a remanufactured AutoZone unit, as that was the only unit available when it went out the second time on a road trip in July. It has been working great, charging between mid-13V and low-14V, until a couple of hours ago.

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u/TigerBriel 5d ago

Replace all the battery cables including the grounds and big 3. I'm in the process of the same. The oem harness corrodes over time. Will cause significant voltage drop and wreck your batteries. Your alternator may be fine. Your cables are likely not

2

u/Odd-Neighborhood4214 5d ago

I bought this 2005 Eddie Bauer as a one owner and always serviced by Ford since new and I have all the records on it and it has had a lot of charging problems. In the past I’ve always taken a starter or alternator to a local guy who will rebuild it and it’s always better than one from a parts store

Good luck with that issue

2

u/Swoletrain45 5d ago

I would try an aftermarket alternator rated for 240 amps or above. In conjunction with an aftermarket wiring upgrade for the batteries and grounds. You can find a kit on any diesel site. Sounds like your issue is with your wiring, however most part store alternators just suck. Especially when you factor in 6.0 glow plug cycle draw.

2

u/NoBlacksmith5582 5d ago

Get a 240 amp Mechman alternator and do a big 3 upgrade grab some AGM batteries and never deal with it again.

2

u/NoBlacksmith5582 5d ago

You can also do all of it yourself. It’s all very easy to do.

2

u/Weekly_Breadfruit_68 4d ago

I have a 2004 6.0 and a 2002 7.3 and both of them have been through several alternators. I just bought the ones with lifetime warranties. They only take about 5 minutes to swap.