Just fried 3rd alternator in a year...

[FOMOCOTOSHO]

Ok I'm not sure what's going on here. I have a 1995 ATX that is relatively stock that I keep frying the alternators. I bought the car just over a year ago and the alternator went out shortly after (it was still the original at that time I believe around 130k) It didn't seem anything out of the ordinary and I wasn't doing any kind of high-revving or anything. I installed a Ford Motorcraft Reman unit.

So this past fall I installed my SCT chip that removed the rev limiter (which I didn't realize when I was trying to see where the computer would force the transmission to shift from starting in 1st gear being selected & going WOT) Woops! I thought the nanny would have kicked in but it didn't, so I fried the relatively new alternator @ about 8000RPM. So I warrantied out with another Motorcraft Reman alternator this fall.

Since that time I have installed the SHO Source UDP crank pulley. The SCT chip does increase my shift point, but it only takes it to about 7200RPM in the 1-2 WOT shift.. the other shifts don't ever crack 6800RPM when u let the computer shift.

So now yesterday while leaving home work I was screwing around with some annoying steriod freaks on their crotch rockets and I was racing them a bit from a few different stop lights (I knew I didn't have a prayer but it was fun) But while slowing down from the second WOT run from light to light, I saw a large billow of smoke or something come out from around my RF passenger wheel/trunk area. I first thought it was my brakes because I just put brand new pads & rotors on and hadn't really broken them in hard yet. However about 3 blocks later my EATC started blinking out on my and my battery light would come on intermittently. F*CK!! I had to limp home as is because it was too late to do anything about it last night so I turned off my radio and all my lights, etc. I got it back to the shop today (I work at an auto repair shop and have access to it after hours) and now only did I fry the alternator, but the battery seems to have overheated or something & it leaked some battery acid all over the battery holder tray. So I not only had to replace the alternator but the battery too.

Any clue as to what is causing this last one? I know the first two times can be explained for the most part, but I'm baffled at this last time, especially the battery.

Any clues?

Thanks for anyone's help

 

[sperold]

What is failing in the alternator? Is it the voltage regulator? Is it the bearings?
Before you send this one away, have it checked by a shop so that you know if high rpm is the culprit, or if the culprit is a bad run of remanufactured alternators.
You might consider a much bigger pulley on that puppy.

 

[deercrusher]

Could it be possible that after your last (second failure) that you did not recharge the battery completely before installing your most recent alternator - which caused premature alternator death?

 

[needaQuaife]

yeah, check battery and all connections and cables to and from battery. check grounds off intake to firewall.

 

[FOMOCOTOSHO]

The diodes are failing in the alternator (at least according to the tests that are run)

Yes I made sure the battery was fully charged before installing it after the alternator was replaced both times.

I've checked all connections & grounds and everything appears to be normal. I have run several complete charging system tests on it after everything was replaced & installed and everything passes with flying colors.

 

[sperold]

I have heard that the diodes get wiped out if hook up the battery backwards momentarily, or, when you jump start someone and they cris-cross the wires.
I think the diodes act like check valves.

 

[CademiaX]

Do you have an under drive pulley on there? pretty sure 7200rpm is going to eventually **** your accessories..

 

[FOMOCOTOSHO]

as I said above... yes I have a UDP

And no I have never crossed the battery cables.

 

[J.L.Gordon]

Yeah,I have the same problem.I just make sure to get the warranty and replace it every year.

 

[nickysho1]

.

try to keep the rpms under 6000. i burned up 4 of them till i started doing that. jusayin.

 

[blue92]

as I said above... yes I have a UDP

And no I have never crossed the battery cables.

Where you buying the alternators from? I had the same problem on my 93atx turned out Autozone's and O'Eeilly's alternators aren't built correctly. I found NAPA's are more expensive but are built much better and after going to the NAPA one my alternator problems went away.

 

[FOMOCOTOSHO]

Where you buying the alternators from? I had the same problem on my 93atx turned out Autozone's and O'Eeilly's alternators aren't built correctly. I found NAPA's are more expensive but are built much better and after going to the NAPA one my alternator problems went away.

The previous 2 alternators were OEM Ford Motorcraft Reman Alternators.

The last one I just put in this weekend now unfortunately was an O'Reilly Ultima alternator because Ford didn't have anymore in stock and neither did any of my Napa stores.

To NickySHO1 -----> Keep it below 6000RPM ??? Are you kidding me?!?

 

[CademiaX]

try to keep the rpms under 6000. i burned up 4 of them till i started doing that. jusayin.

I'd have to agree, if you are driving 6000+ rpm regularly on the road, you are doing it wrong.

So now yesterday while leaving home work I was screwing around with some annoying steriod freaks on their crotch rockets and I was racing them a bit from a few different stop lights (I knew I didn't have a prayer but it was fun)

Street racing... really, come on now, you should know better.

Any clue as to what is causing this last one?

second WOT run from light to light

You answered your own question

To NickySHO1 -----> Keep it below 6000RPM ??? Are you kidding me?!?

Ya, get off the road before you **** someone or yourself.


Final Thoughts:
Sell your SHO to someone who will have some respect for it and the law.

 

[FOMOCOTOSHO]

I wasn't asking for your opinion on my driving, I was looking for technical help. Keep your opinions to yourself.

FYI this was a brand new empty road with no traffic. and I never exceeded 50mph the entire time.

 

[CademiaX]

technical help = stop driving like a retard.

 

[SHOtime2511]

technical help = stop driving like a retard.

STFU,quit being a tool bag.
perhaps we should all sell our high revving sport sedans and buy used
Jetta TDI's?

 

[FOMOCOTOSHO]

Well as of yesterday make that #4 ! Dammit this is ******* me off.

Does anyone know of anything more heavy duty than the Motorcraft alternators? I've also tried Napa & O'Reilly ones but those were even worse.

I don't know what else to do. The car redlines @ 7200RPM with the chip but I have a UDP so why do they keep frying? GRRRR

 

[Eric VerValin]

lol I got UDP's on my car... full set.. never had an issue... it should spin slower not faster... so there shouldnt be an issue... I wonder if when it idles if the low speed dosent hurt it more.

It's gotta be in that charging circuit somewhere.. I'll pop up my CD here in a while and see if there is something simple we're all over looking...

 

[FOMOCOTOSHO]

**UPDATE**

I think I found the problem today!!!! Or at least I hope...

I was replacing the alternator again today and I decided to replace the connector plugging into the alternator. I checked with Ford and it is discontinued (no surprise there) so I went to the local salvage yard and cut one off. Upon peeling the wire wrap back one of the wires pulled out.... when I unwrapped it further I found the wire were connected with butt connectors! Someone had replaced the connector already once before for some reason & used stupid butt connectors. So I'm assuming something was shorting out or wiggling loose & not getting a good connection.

So I'm quite confident now my issue is resolved but I guess time will tell..... If I follow my previous schedule of frying alternators, they would only last about 3 months so I guess I will know my Halloween!

Thanks for everyone's input & help on this. I appreciate it.

 

[hawkeye18]

I'd have to agree, if you are driving 6000+ rpm regularly on the road, you are doing it wrong.



Street racing... really, come on now, you should know better.




You answered your own question




Ya, get off the road before you **** someone or yourself.


Final Thoughts:
Sell your SHO to someone who will have some respect for it and the law.

There's a crocheting forum over that way --->. You should go there. Slowly. In a '95 Lincoln Town Car.