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Old 11-13-2006, 10:01 AM   #11
CaysE
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You can call any Ford dealership and give them the part number above. They may need to order it in, but it should only take a day. The problem is there's a fusible link on one of the three wires that plug into the alternator. It rubs against the wire loom and causes a break in the wire. The install is fairly straightforward:

Remove the negative battery terminal connection.
Unplug the 3 or 4 connectors that are in the way.
Unplug the vaccuum line that's in the way (fuel pressure sensor?).
Unplug the 3-wire alternator connector. Remove the electrical tape and pull back the wire loom. You should see one wire has a fusible link on it.
Unlatch the main wiring harness from the firewall. You have to pop the harness out of 2 or 3 clips. This lets you pull the harness higher up so it's easier to solder.
Cut the 3 wires behind the fusible link (about halfway to the main harness). KEEP THE CONNECTOR! The replacement part does NOT have color coded wiring!
Keeping note of which wire goes where, cut the new plug's wiring to length, strip the ends, solder, and heatshrink.
Re-mount the main harness, plug everything back in, and you're good to go!

Last edited by CaysE; 11-13-2006 at 01:38 PM.
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Old 11-17-2006, 03:50 PM   #12
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Today I did some inspecting and found the red wire was not connected to the alternator clip. Going to Ford now to pick up the part (1U2Z-14S411-TA) and will hopefully have it running again soon.
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Old 09-21-2010, 12:05 PM   #13
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Thread Resurrection...
Mainly for the question below, and also so I can update the "How To" at the same time.

CaysE; (or anyone else)
Are you sure there's a fusible link in one of the three wires going to that connector??
(I thought it was only the + cable from the battery to alternator that had a fusible link)
I've got my 3 wire connector opened up all the way to where it goes into the main harness on the firewall
(about 6" from the connector to the junction), but I don't see any sign of a fusible link.

I suppose once the replacement pigtail gets here tomorrow it might be clearer,
but I really want to make sure there is a link in there, and that it gets replaced with the new wires.

Last edited by WD40; 09-21-2010 at 02:10 PM.
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Old 09-23-2010, 12:57 PM   #14
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Maybe the '04 had a different harness, but I'm almost positive there was a small fusible link on one of the wires I replaced just an inch or two from the connector to the alternator. It's been a long time since I replaced mine though. Fusible links on wires this small are pretty thin; maybe you overlooked it?
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Old 09-23-2010, 01:08 PM   #15
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Thanks for the reply!

I just got done putting a new pigtail on last night, and I sure couldn't see any fusible links on the new one, nor on the old one.
I left about 3" of wire from where it goes into the main harness (that's about 1/2 of the exposed wire),
and soldered the new pigtail from there on.

Regardless, looks like I'm getting OK signal now from the grey wire (6 volts), and a full 12volts from the red wire
but I'm still dead in the water at 12.8 volts when running.
Oh...readings for grey and red were taking with KOEO, and disconnected from alternator.

When conected (KOEO) the volts drop down to <1 for the grey wire.
Running, it starts at 2 and goes up to 4 depending upon how many accesories I turned on.
But...still that measly 12.8 volts at the bat or + terminal on alt, no difference.
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Old 09-23-2010, 01:27 PM   #16
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The replacement pigtail doesn't have a fusible link, I know mine didn't. But the original harness did have one.

In any case, if you're only getting 12.8 volts when running, have you checked the main charging wire? It tends to snap right where it bolts to the extension post on the alternator.
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Old 09-23-2010, 01:31 PM   #17
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Quote:
Originally Posted by CaysE View Post
In any case, if you're only getting 12.8 volts when running, have you checked the main charging wire?
It tends to snap right where it bolts to the extension post on the alternator.
Yes, I inspected it pretty good when I put the new alternator on.
I also ran a separate "dedicated" lead between the battery and alternator, and got no change in output.
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Old 09-23-2010, 01:46 PM   #18
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I guess changing the alternator is all that's left to do.
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Old 09-23-2010, 02:42 PM   #19
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^^^BTDT.
And, I started a new thread, since I didn't want to jack this one and get too far off your original wiring kit discussion.
http://www.focusfanatics.com/forum/showthread.php?t=240870
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