Volvo :: No Power Coming From Alternator / Not Charging


May 11, 2009

About 5 months ago had a friend who I had to boost a bunch cause he kept leaving his lights on. his alternator was dead after a while and he borrowed my battery to get him to the service station. two weeks later my battery died. I bought a new battery from advance.

everything went fine other than a small headlight/tail issue that's been with the car since I bought it but never seemed to present itself other than one tail light never working and one headlight not working.

about 2 weeks ago i stopped at a filling station and my car wouldn't start.

battery checked good, alternator was bad. got a used alternator off of another volvo i own (same kind, reman off of a 1989 740GL) at first the alternator was reading low at 11.5 volts, i decided to chance it and it failed me on the highway, went back with a fresh battery the next day and drove it home. now I have since had the alternator at two places, at some old timer electro mechanic and he said it read 14.5...didn't trust him....went to the new autozone and they tested it as PASS at 14+.... put the alternator back on the car and it's still not charging.

the car runs fine other than it ain't charging. the alternator failure light is on, along with the two brake lights and bulb failure (which is to be expected because of particular system construction).

is there a fuseable link that might be burnt through? is there any other main voltage lines or regulators I should look for? main fuses?

1987 Volvo 740GLE 400,xxx miles. New Battery, 2003 Reman'd Alternator, 2004/5 replaced postive terminal and wire, countless number of small electrical flaws.

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I ve been noticing that the alternator isn't charging correctly, or at least it seems like it. We drive short trips sometimes two times a day, a mile or less. One day, night actually, I noticed it started to not turn over with it's usual enthusiastic sound. When the batteries get discharged to a certain point, the voltage at idle will be less than 12 volts. If I rev the engine for a bit, the volts jump up, but at idle it drops back to 12 or below. Seems to me that it should be at least 12v or above if the batteries are discharged, and more towards 12.5ishV if the batteries are fully charged.

After I put it on a 6A charger overnight, the voltage upon starting is above 12, sometimes over 13. But if the batteries start to dwindle down from short trips, the voltage drops to 12 or below at idle.

I did install the smaller pulley a few years back, and that worked massively. I couldn't get 12V at idle before installing the smaller pulley. But now it seems like I'm back to that same situation before installing the smaller pulley.

So, I m guessing that a alternator bench test is in my future? The batteries are fairly new, tho they have been down to nothing at least twice from boneheaded moves by yours truely!

And, I'm speculating that this charging situation contributed to the recent FICM replacement that I went thru.

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So far, tried 2 new alternators, (rebuilds), 3 batteries and several diagnostic sessions which have been inconclusive. What I do know is that when the charging system is not working, I still have full battery voltage on the Y/W and LG/R wires on the small wire plug at the alternator. The path from the alternator output through the megafuse to battery + does seem to be intact. Measures full battery voltage and even tried a test by using a battery booster cable to connect the alternator output directly to battery + when the system was not charging.

No change with this test. Visual inspection of the engine to firewall ground strap and the battery - to rad cradle ground wire seem to be OK. Have not had the opportunity to try the jumper cable trick to verify the alternator case to battery - circuit, (darn intermittent!). There did seem to be something intermittent related to a wiggle test in and around the power distribution fuseblock, but once again, this was inconclusive. I also was able to make the charging system fail, (once) by turning on the headlights and blower motor.Any specific failures that may cause this? Not much left to change or check!

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Also, I put a DC volt meter on the negative side of the battery and the positive side of the CHARGING wire that would be connected to the alternator and got the same reading as if I put the meter on the positive of the battery.

Does this mean the fusible link is good?

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The alternator has been tested and works. The voltage regulator is new. This is how it is currently wired.

Regulator A Terminal --> Battery side of started solenoid --> Alternator Batt Post
Regulator F Terminal --> Alternator Fld Post
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I *think* I'm having trouble with the alternator on my 2002 Navigator with the 5.4L DOHC engine.

A year ago in Feb 2014 the alternator quit charging. I thought the headlights were a little dim, but when the radio turned itself off and then the heater fan did the same, I noticed that the alt light was on. Then the engine shut down about 1.5 miles from home.

I'd heard of war stories about rebuilt alternators so I sprang for a brandy new one. I also got a voltmeter that fits in the cigarette lighter so I can monitor the system voltage. All seemed good and the new alternator put out 14.2 to 14.5 volts. Except that the battery never seems to be fully charged. If I check the battery voltage with the engine off it typically reads 11.9 to 12.2 volts. I had Interstate Batteries check the battery. They thought it was okay, but offered to put a new battery in to keep me happy.

Six months and 8,000 miles later I'm up in Ontario back country (on vacation - no tools in the truck) and I notice the engine idles at 900 RPM instead of the usual 650 +/- RPM. Oh-oh, I also notice the volt meter is reading 11.9 volts and drops a tenth about every 10 miles.

Found a shop that was open and they installed a rebuilt alternator and it was putting out 14.2 to 14.5 volts. All was good (except for my wallet!).

Now, here we are six months and 5,000 miles later and the rebuilt alternator is struggling to put out 12.5 volts this afternoon. At a steady 50 MPH with the cruise Control on, the radio, and the heater fan on low, the voltage is bouncing between 12.2 volts and 12.7 volts.

Now to my questions:

1. Shouldn't an alternator put out 14.2 to 14.5 volts all the time? Not just when the alternator is new?
And
2. Is there anything on my truck that could be killing these alternators? Or am I just unlucky in the alternator lottery?

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I have batteries from 2015 that are losing their charge, both of them. It's like the alternator isn't charging them. Truck will struggle to start until jump started, then she's fine.

Symptoms are:

ABS light comes on when as best I can tell the batteries aren't getting charged. Not the battery indicator.

Now that the batteries are low enough, on the instrument cluster the little light the powers the mile LCD screen dims when it's not getting power (but it's fine when the batteries have charge.)

All accessories work when driving, but I haven't been able to drive a long while on the "not charging phase" to see how low they're go.

Batteries register dead (now) because they haven't gotten charge in a while.

When the alternator IS charging or "connected" I can leave the truck idle and she'll charge the batteries, truck will start just fine on the next run (no parasitic drain.)

Driving causes this to happen randomly, doesn't happen when I'm stationary, nor do I believe it CHANGES state (so if I'm idle it won't suddenly NOT charge if it was charging before.)

Narrowed down to 2 probable things.

Alternator
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2003 F-250 V10 6.8 liter 255,000 miles.

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