Ford F-150 (2004-2008) :: Battery Light On And Whining Noise From Pulleys


Feb 4, 2016

I have 2005 F150 XLT 5.4 litre engine and my battery light comes on after letting the truck run on idle or sometimes driving.

Last Saturday went out drove it heater on and radio on I smelled something coming from the heater kinda like burning wire smell didn't think anything of it no smoke from heater (indicating the core was bad) no lights on the cluster nothing; went into the bank let it run came back out my battery light on. Drove it home and while driving the light goes off.

Opened the hood and the smell was coming from the alternator. So I turned the truck off. Let it sit for an hour or so then I took my voltmeter to see if the battery was good. The battery was 12.4v with engine off. Checked my battery connection for corrosion or loose connections everything was tight there was some dust on the battery terminals so I brushed them off. I checked the battery cable that goes from positive to the alternator where it connects to the alternator with that nut it was good, clean and tight.

So I started the engine up and I can hear a whining noise from one of the pulleys. Let it idle for 2 minutes no battery light so I put my voltmeter on the battery it read 13.8v, so I turned on the A/C, head lights, radio and the heater tried again the voltage dropped down to 11.9v then the battery light came back on. Also through all this my battery gauge in the cluster always stays a half way mark doesn't drop or go high. Next with the engine turned off I took the belt off checked the pulleys the idler pulleys seem fine and the belt doesn't show any glazing but the alternator was hot almost like touching a hot exhaust manifold.

So for the last 3 days I have been trying to come up with how to resolve this issue obviously it could be the alternator going bad but the battery has never lost a charge yet I let the truck sit for these past 3 days and today I started the truck and it started right up I don't see any dimming lights except it has a whining noise and the battery light didn't come on immediately I let it run for 5-10 minutes before it came on; I even drove it around the block and the whining noise gets louder every time I step on the gas. To me it's either I need new alternator, tension pulley is bad or the idler pulleys are bad but they turn fine.

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So about 3 or so weeks ago I brought my 2006 GX470 into the Lexus stealership and had the pulley's, water pump, and timing belt replaced. Fast forward to this morning, about 300 miles driven and it suddenly when started today has a terrible whining sound and the battery light is on the dash.

I need to go over the invoice from what they did but I believe it was 4 different pulley's they wanted to replace. Not sure if it was anything on the accessory belt path, but I imagine if I call they will blame the alternator and tell me to shell out hundreds more?

I didn't run it long like that, only a minute or so. Popped the hood and I could smell the burning rubber smell so I quickly shut it off. Nothing *appeared* seized to me however.

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Is this something serious like my transmission on its way out? From what I gather a lot of people seem to have a similar thing going on.. From what I can remember my truck has done this since I bought it, but lately (and maybe its just me) I seem to notice it more like maybe its getting louder..

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SO WHO has changed alternator and how hard was it? Im looking for it and I think its under the Power steering pump it seems left side engine looking at it.??

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I'm new here to the F-150's forum although I've owned a few since 2001. I bought this F-150 '05 5.4L Lariat. Really nice truck. But when I purchased it, it had this weird noise inside the cabin. I thought because it had a camper on it that some tranny noise was coming up thru the camper and the rear cab. After taking camper off, the noise was still there. From everything I've read online, it could be rear pinion seal, differential bearing, tranny, front hubs, etc. I have left a video. Pay close attention to the little whine. Kinda hard to hear if your not listening for it.

Note- when i drive it is most definitely coming from the middle to rear of the truck. But I'm not ruling out anything. I have looked underneath the truck and the differential is dry and the driveshaft area near diff is dry. No leaks. I have not checked fluid in diff. Is there an easy way for these trucks? I have read and heard about adding an additive? The noise starts at about 10-15 mph all the way up to 80. I've never taken it past 80 but I'm sure it's still there.

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Today when I got home after a 15 minute highway drive, i got under the truck and felt the differential area. it was warm but not hot. and there was a wet spot on it. i wiped off a drop of oil. there was also a wet spot on the bottom, seemed to be just water? I'm not sure.

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Its on a 2005 Super Cab with the 5.4L 183,000 miles. The front pinion seal was replaced in Feb 2 years ago, by the dealer's mechanic, who may have been a shade tree mechanic.

I am a Youtube Certified Mechanic, as in, I watched about 10 videos of people working on their 9.75 differentials, and realize I don't have all of the tools to do the job, such as a press, or race drivers, or the special gauge.

How many of you have tackled this issue? What did you find? What am I looking at for cost? I am on a very small budget.

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Truck is auto engaging the AWD after 30 seconds of driving, if I reset it back to auto, it locks AWD 30 seconds later.

If I'm driving above 30-40 MPH this gives a pretty intense whining sound. I assume overheating the system. Last test drive put it in AWD disabled mode- I assume from overheating.

Truck wants to auto lock AWD no matter what, I don't seem to be able to do anything to prevent this other than turn OFF traction control- which then ends up disabling the auto AWD and telling me to see owners manual as well.

Truck does pull a little from needing ball joints, but would this tell the computer to engage the AWD constantly ? Any thoughts?

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Well it's back. Now I have a noticeable whine in the cab. I haven't pin pointed it yet. It is only audible when the truck is running from 35-50 mph. It is not RPM dependent, it doesn't change when I take it in or out of four wheel drive. It isn't there when the truck isn't moving.

The truck has 61,000 on it. I bought it with 35,000 on it because I wanted a vehicle that wouldn't nickel and dime me. Something I could climb in and not worry about making home.

Well here I am less than 30,000 miles later and I have had issues with the fuel controller under the bed, brake calipers sticking, IWE's, new shocks, broken front coil spring, recall for the airbag, tie rods, ball joints, power window regulator, and now what appears to be a transmission.

I come from a long line of "FORD" guys, but I am seriously considering something else. This 04-08 model has to be one of the worst pickups ever built by ford.

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I have battery on charger now. I assume the BCM is the regulator by feeding current back to the field? If so could the growling be the BCM feeding back a huge field and the rectifier bridge growing? And the BCM fuse blew because too much current to alternator field coils? Will it start with a charged battery with the BCM dead? I need it to run to get to the parts place. Which fuses do I need to check? Then, how do I check the alternator, wiring, BCM regulator to find original problem?

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