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Old 01-10-2014, 09:21 PM   #1
crazy-coyote
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Electrical problem

I have a 2005 zx5 with a 2.3L with 113000 miles. It's stock besides a Kenwood stereo which I installed. Its having an intermittent electrical problem. The battery saver relay will start clicking, interior lights will dim, Headlights will flicker, under acceleration the engine will cut out like it is running out of gas, sometimes the battery light will come on. Most times I can pull over, Shut the key off and restart and will run fine the rest of the day. So far I have replaced the battery, checked and cleaned all the grounds I can find, cleaned the battery connection, replaced the positive cable end which has frayed a bit, switched the battery saver relay with the horn relay which is identical. Everytime this has fixed the problem for about a week. I took it to the Ford dealer twice. They got a p1235 code but couldn't find anything wrong with the fuel pump or module. They could not replicate the problem and said the charging system was working fine. It happened again this morning and I had a scan tool with me. Normally while driving it shows 14.5 volts but this morning it showed 12.5 when it was acting up. And the check engine light came on which was the p1235 again. I pulled over and restarted and drove to work with no more problems and 14.5 volts. My best guess is the alternator. Any help would be greatly appreciated.


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Old 01-10-2014, 09:45 PM   #2
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Alternator may be on its way out. Might be a short/bad ground causing the drain. I guess alternator.
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Old 01-10-2014, 10:42 PM   #3
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Pay no attention to any codes that come up. They are false and a byproduct of low voltage.


It sounds like an alternator failing. But it's odd that it's intermittent.
Simply turning a key off then on won't fix a wiring issue. So you should be able to rule out the pigtail.
The more I run scenario's through my head the more it sounds like a slipping belt.

If it were something RPM based, you'd be able to replicate it at any time. You can't.
If it were heat related it happen any time the car gets warm. It doesn't.
If it were wires rubbing or grounding out, simply stopping and restarting wouldn't change a thing.

So a slipping belt is about the best I can come up with.
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Old 01-11-2014, 10:06 AM   #4
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Hey guys, thanks for your replys. I haven't thought of a slipping belt. Ill have to check it out.
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Old 01-11-2014, 10:48 AM   #5
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check the + wire on the back of the alt mine corroded and worked for a bit w/light coming on alot then it completely broke off from the alt and the car died completely.
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Old 01-12-2014, 04:14 PM   #6
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Check the hatch harness where it passes through from the hatch to body for cracked wires. It looks kinda like an elephants trunk. Pull it back and inspect.

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Old 01-21-2014, 07:59 PM   #7
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I inspected the wires to the alternator and didn't see any problems. I did the wiggle test with the engine running and that didn't cause any problem. The belt is in good shape and tight. I checked the hatch wires and sure enough one wire ( I think the green with blue stripe) was missing some insulation. I taped it up good and drove it 400 miles without a problem..... till today. It was acting up all the way to work. So Im out of ideas again.
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