2016 Expedition EL check charging system warnings 2 alternators later...

[daftdesigner]

We picked up a 2016 Ford Expedition EL a couple of weeks ago, and it was just in to replace its second alternator after "check charging system" messages started lighting up the dash.

We bought the Expy to tow our travel trailer ahead of a 6 week road trip - just me and my 4 kids - through Idaho, Wyoming, Montana and Washington before returning to Portland.

30 miles outside of Meridian, the dash threw the same "check charging system" message. I spoke to our dealer and a couple of local Ford shops and am trying to sort out what to do:

1. Local dealers can't get me into for a week or more... so lie in wait and pray for the best.
2. Hobble home and get the dealer to work on it again. Tricky as the last time we spoke there were no alternators around.
3. Discuss a trade either here in Boise or after hobbling home (and praying for the best).

My kids and I are heartbroken about this - just not sure what is the best plan of attack.

 

[ExpeditionAndy]

Just for the heck of it, check for loose battery cables and connections at the alternator. Make sure your ground connections are tight too.

 

[Big Brian]

...and make sure the terminals and battery posts are clean and shiny bright

 

[stamp11127]

Buy a battery charger and a digital multimeter. Enjoy the trip - when you set up the trailer also charge the battery. Use the multimeter to monitor the battery voltage the next time the warning comes on and throughout the day. Minimum charging voltage with the engine running is 13.5 volts dc. A battery is considered discharged at 11.8 volts.
Problem may not be the alternator. Could be loose connections, electrical harness or ecm. A msster tech should troubleshoot the problem instead of throwing parts at it.
To lengthen the run time on the battery if it isn't being charged you should reduce the electrical load on the system by turning off accessories.

 

[bobmbx]

Unhook your tow and drive around. $10 says the fault is on your trailer or in the electrical connection to your truck.

 

[powerboatr]

mulit meter to check battery and if its its getting a charge with engine running and trailer unplugged.
after you check all battery connections , that means removing them and then reattaching.

 

[Big Brian]

I would not be taking it on any trip with the light on and not knowing if its charging or not. If a voltmeter shows that it is charging then fine, go on your trip.

A battery charger and voltmeter wont do you any good if it dies on the side of the road.

If the dealer cant get you in try an independent repair shop since you really need to get this fixed asap.

 

[daftdesigner]

UPDATE.

This is getting ludicrous.

Took it into a dealership near Boise and they could not replicate the issue and told us the truck was working fine. Made arrangements to store the trailer at a friend's near Sun Valley and after making it to their place without an incident, the messages started again after trying to run to the store.

Ford sent me to a local dealership (great people) who looked as the truck and are saying that there are clearly faulty circuits (not sure why they can see this and the dealership in Boise cannot). They cannot get to the truck for 10 days though. Ugh.

Trying to get Ford corporate involved - but they moving sluggishly. Any thoughts or suggestions would be much appreciated.

 

[ExpeditionAndy]

Is it still within the factory warranty period? If not, do you have an extended warranty? Call all of the dealers around you and explain that you are on vacation and need to get it fixed. See if someone can get you in. If it is too far for the truck to make it, put it on a rollback and send it to them. I can't believe that a dealership can't work you in, in an emergency.

 

[1955moose]

You may need to get the bureau of automotive repair, or an attorney involved in automotive, it's amazing how managers jump up and get things fixed when attorneys get involved. Push come to shove they should hook you up with a rental.


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[gixer2000]

I was having this issue on my 07. Not sure how different the charging system is but the 3 wire harness that runs to the alternator was where my issue was. The pins were loose in the plug and it wasn't sending the alt output power to the pcm. It took like a month to find it because it was intermittent but it was throwing a P0625. I'm also 2 alternator deep and once I replaced that plug all is good.

 

[daftdesigner]

The truck is under PremiumCare, but the attention we are getting from Corporate is terrible. The small local dealership is totally stepping up and working on it and as of this afternoon, the selling dealership is also actively involved.

I will update once I learn more.

 

[1955moose]

Smaller shops usually are better. Keep us posted.


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[gixer2000]

Unfortunately issues like this are tough because the alternator send signals to and from the pcm (gen Mon,gen com and B+) B+ is just battery voltage but gen Mon/Com need to be measured with an oscilloscope. If the issue is intermittent and not showing on the oscope they'll just send you packing.

Any idea what the code is?

 

[1955moose]

It's funny what gixer said about the pins. Years back when I was running a Harley rental in San Fran, we had a brand new Electra glide that had to be towed in twice. The first time the dealer thought it was fixed. Second time their top tech found a bent pin straight from Milwaukee that slipped through, and was causing it to lose spark. Took as much as 400 miles to act up. Thank god I didn't have to find that one. Yours is probably similar, an overlooked easy connection. Chances of 2 dealer alternators bad would be astronomical.


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[gixer2000]

It's funny what gixer said about the pins. Years back when I was running a Harley rental in San Fran, we had a brand new Electra glide that had to be towed in twice. The first time the dealer thought it was fixed. Second time their top tech found a bent pin straight from Milwaukee that slipped through, and was causing it to lose spark. Took as much as 400 miles to act up. Thank god I didn't have to find that one. Yours is probably similar, an overlooked easy connection. Chances of 2 dealer alternators bad would be astronomical.


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Its so common across all manufacturers it not even funny because it could take months to find stuff like this.

Knowing the exact code may help me tell you what pin you should be looking at

 

[daftdesigner]

I will try and get some details tomorrow.

 

[stamp11127]

And that is why I love electrical work. Hours to find the problem & minutes to fix it. Then the Kodak moment when they ask how much?

 

[jeff kushner]

And that is why I love electrical work. Hours to find the problem & minutes to fix it. Then the Kodak moment when they ask how much?

Isn't that the truth! Time is money but most of us have been on both sides of that equation.

We as owners want and expect the manufacturer to be able to diagnose and solve the issue quickly then affect the actual repair.....but most of us have a bit of heartache paying for the Diagnose & solve part but in reality, that's all time the mechanic isn't making his boss money doing something else so he's fair to charge for it.

I think it's getting better though...in the 80's & 90's, most dealers hired "parts changers" and YOU got to pay for their incorrect diagnosis....it seems not to be quite as bad as it once was.

jeff

 

[stamp11127]

Nope it has gotten worse. Now the techs need to know not only the product they need an understanding of electronics and computer operation. Most hate it and do what the scanners tell them - right or wrong. "But the parts were bad anyway..."