Charging system issues

[VA epxy]

Hello Noobi here with issues.

I bought a 2010 Expedition EL limited about 2 months ago, and since day 1 have had the Battery Light "Charging System" light come on intermittently. The dealer has replaced the alternator twice, the battery, and the PCM ( they even reset the PCM per factory standards) and still the light will randomly come on at times.

It can be on the highway, and it can come on and stay on until the car is shut off. Or after a drive to the store, it will sometimes come on while idling in the parking lot.

Sometimes it will stay on until the car is shut off, sometimes it stays on only for 5 - 10 seconds.

It happens daily, but does seem to happen more often the hotter it is ( when all A/C is blasting)

I would appreciate any ideas or suggestions. Does anyone have similiar issues?... Ive searched the forums, and heard some people mention a blinking charging system light but havent seen any fixes (if this is a sim issue)....
Its a beautiful car with every option imaginable...which is why I have let the dealer try to fix the problem...because I cant find another car like it locally. I would like to keep the car, but at this point it has been in the shop longer than its been in my driveway.

 

[toms89]

I assume they tested it and confirmed it is a charging problem and not a fault with the indicator light circuit..?

 

[Thermo]

VA Expy, I would tell them to test the field wiring. If you have a higher than normal resistance in that, your alternator will have issues with outputting its maximum current since the field will not get the full 12 VDC to it. Atleast on the older expy's, it was a tan and yellow wire that ran from the mega fuses near the battery to the alternator. It had a 10 amp fuse in line with it. I bet you will find that to be your issue. All the symptoms you are describing sounds like it. Otherwise, your problem is a bad cable running between the alternator and the battery. But, this should be fairly obvious because the cable should be getting pretty warm and what you will see is a bunch of darkened cabling at a specific point in the cable. Right after driving the truck, you should be able to run your hand along the wiring. For the most part that wiring will be warm (because it will be at the under hood temp), but where you have an issue it will be extremely hot (like get close and you will be in fear of burning your hand hot).

 

[Heavy_Set]

Well I'm not going to go and get as in deep as Thermo but try this also, look at the alt plug. The plug that is pluged into the alt itself. Look to see if the wires that are in the plug are all pushed into their slots tightly. One of them may not be making the proper connect due to it not being locked into the plug housing itself. This was an issue that I faced on mt Lincoln TC. Had to replace that plug which fixed my problem. If this is the prob go to CarQuest they may have to look up the part number in the book but they will have it. Hope this helps.

 

[VA epxy]

Thank you for all the suggestions, I will print them out and show them to the dealer ( where the car is currently).
I will keep you posted of the outcome.
Thanks again.

 

[VA epxy]

So I just wanted to take a minute to reply, to possibly help others.

After a few days at the Ford dealer, they traced every wire and found there was a wire in the steering column that didnt have a nut holding the wire on. So it wasnt getting a good ground and was intermittently draining the battery.

Sorry I cant provide any more details, I didnt get a chance to talk to the tech.

 

[GAINMOB]

thats good enough...so now if anyone has this prob they can ask about if theres a wire loose in the column

 

[Thermo]

Ah yes, our trucks are notorious for having wiring issues in the steering column. I bet you like to raise and lower your steering column when you get in and out of the truck. Am I right? Seeing that problem does not surprise me. Granted, it normally shows itself with funky responses to the wipers and lights.