just got done with some serious drive train work, [trans Tcase]
Had my gauges out to put the TrustZ ones in Alternator was charging and all of a sudden it isnt now..... WTF it was rebuilt with OEM parts less then 4k miles ago...
The battery light on the gauges Does NOT light up, also it does not light up when you turn the key to on either... I have replaced the bulb and still the Same ****... Im getting Ill of this car already seems you fix one thing and something else Fails.

Any ideas anyone? i was going to jump pin 9 and 19 with a 100OHm 5W resister to simulate the gauge cluster for the Alternator Start wire.BUT on the connector the color code of wires does not match the Diagram.... it calls for a orange and then a red wire.. i dont even see a Orange wire to the gauge cluster WTF...

 

If nothing is lighting up with the key in on, then something isn't right with the battery, or the wiring associated has blown a fuse.

The alternator obviously only charges when spinning. I have to be misunderstanding you here... how did you test the alternator?

 

ive got a voltage meter on my Turbo timer,
What bothers me is the battery light on the dash is not going on when the key is first turned to the on position.

i have checked the 7.5 amp fuses, 100A alternator fuse is good. Issue is the Alternator is not get excited by the ECU, cause the light on the dash is not going on when first turned to on.... Im thinking bad wires from ECU to
alternator

everything lights up BUT the battery light btw., even the brake light is the brake is applied.

 

drivetrain work = engine grounding strap?

 

i have double engine grounding straps, It charged for the first test drive now its not

as i was looking it over now i checked the alternator pigtail connection and it looked good, so i pulled it apart and test everything it was all good..... so wtf, i pluged it back in and noticed the Green Wire get pushed back thru the connector! nasty little SOB, the connector is bad it looks like wow good thing i was looking and tugging on the wires or that would have taken me forever to find.

now where to find a new connector...

 

That was a common problem with Ford Explorers turn signal harnesses in the 2000's. I would suggest plugging the harness back in, if you can get the wire in so that it makes contact, do that, and then hot glue the wire into it's harness.

Don't mistake what I'm saying. You aren't gluing the harnesses together, you're gluing the wire back into the harness that it sits in.

Kind of like this...

 

But on a more precise scale.

 

less is more in this case

 

Got it thanks, now lets hope i dont spill hot glue on myself

 

It looks like a 10mins fix man and glad you find the problem.

 

Yeah. The issue with the Ford's were that every time you tilted the wheel, it was working the wires out of the clip. But the added hot glue was an easy enough fix, and it worked great.

Also... don't get electrocuted lol.

 

It worked! Im almost at a point to where i wanna do the harness like Antilag did, but DAMN that was some serious work he did, BUT it came out soo nice.