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Charging system issue

thebrakeman

Explorer Addict
Joined
February 11, 2009
Messages
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City, State
Canton, Michigan
Year, Model & Trim Level
2006 Mercury Mountaineer
Long story, but want to give you everything I've checked, and conditions:

2006 Mounty with 109,000 miles. My wife is the primary driver.
She let me know a few weeks ago that she was getting a Charging System error in the Info Display. I have seen it once or twice since then, although whenever I had a chance to check voltage, it was always fine.

Took it to Advance Auto to get the battery and alternator checked. (The 84-month 850CCA battery was purchased at Adv.Auto Nov 2010). The guy took some general voltage readings (fine), then hooked it up to the gadget. CC amps was in the high 700s and was charging fine, and the alternator checked out.

This past week, my wife was coming home, and she said she lost all instrument panel lights and instruments, as well as window/lock control. Basically all non-essential assessories were gone, but the vehicle continue driving fine and got her home without issue. I'm guessing this is some sort of limp-home mode, to conserve energy, when the system senses that something is very wrong.

That evening, I checked the battery, and it was dead...under 12volts. I jumped it from my car. After disconnecting jumper cables, alternator output was 13.5volts. Every time the truck has been running the next day or 2, alternator was the same, until this morning. I let it run for a good while, drove it around for 15 minutes to let charge. After a couple of hours (off), charge was 12.5V.

This morning, battery was down to around 12.2 volts. I took off the battery cover, and was surprised to see access plates to check the water. I thought this was maintenance free. Anyway, popped them off. First 3 holes were good, next 2 were a little low (right at the top of plates), and the 6th was below a plate. I topped them all off with distilled water. Truck started fine, althought I noticed the alternator was now putting out 14.4volts. Went to Kroger this morning. 15minutes later started fine again and got to work. 4 hours later (right now), resting battery voltage is 12.3volts, which seems a bit low to me.

I'm going to keep driving this all week at least. Could that low water have been the problem? Alternator seems to be fine, but I don't know why the truck would have gone into bonkers mode unless the alternator wasn't putting out. Do alternators usually die quickly, or do they start out with intermittent issues?
 






Sounds like the voltage regulator on the alternator is failing to me. The output on a good alternator should always be around 14.4 v in my experience with these vehicles. On my '77 Dodge truck I have had to replace the voltage regulator several times because of funky things like the battery running dead because the alternator wasn't charging it at all. In other words the vehicle was running purely off the battery and a vehicle can run for a while on just the charge in a battery.
Also, you really shouldn't add water to a battery unless you have a hydrometer to verify the cell needs it and slightly low water in a cell wouldn't cause the battery to drain.
 






Voltage regulators that I've seen go bad allow too much voltage. Sounds like the OP's problem is not allowing enough voltage and under charging the battery. With that said, it would be worth bench testing the voltage regulator too. It's also a free service at parts stores. Should allow the alternator output of around 13-14.5v

My guess is a loose or bad connection. Start at the negative battery post and trace back from there.
 






Problem seems to be resolved

Thanks for the recommendation to trace the wires to/from the battery. That was good to do before paying for anything. Everything that wasn't buried inside a harness was tight.

Took the alternator to a rebuild shop, and based on the symptoms, they recommended changing just the voltage regulator, which only ran $40. This part also serves as the brush holder, so that included new brushes as well. The tech said that everything else looked good inside, and still did not recommend the full rebuild.

5 days in, and problem seems to be resolved. I also took the opportunity to change the serpentine belt, and checked the tensioner (which was fine).

Thanks all.
 






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