Alternator - Discharge

Article No.
96-21-4

10/07/96

^ CHARGING - GENERATOR DISCHARGE - LOOSE OR WEAK CONTACT AT GENERATOR HARNESS CONNECTOR

^ WIRING - GENERATOR HARNESS CONNECTOR DAMAGE - LOOSE OR WEAK CONTACT

FORD:
1985-90 ESCORT, TEMPO 1986 TAURUS
1986-90 CROWN VICTORIA
1987-92 THUNDERBIRD
1987-93 MUSTANG

LINCOLN-MERCURY:
1985-87 LYNX
1985-90 TOPAZ
1986 SABLE
1986-90 GRAND MARQUIS, TOWN CAR
1987-92 COUGAR

LIGHT TRUCK:
1985-90 BRONCO II
1985-91 AEROSTAR
1986-91 ECONOLINE
1986-92 RANGER
1986-93 BRONCO
1986-94 F-150-350 SERIES

This TSB is being republished in its entirety to update the Service Procedure outlined in the Action.

ISSUE:
When a generator fails, there are a few failure modes that may cause heat to be produced at the wiring harness-to-generator connector. This excess heat may damage the female terminals on the wiring harness, resulting in increased resistance. The increased resistance produces more heat. When the generator is replaced, the resistance produced by a damaged connector may damage the new generator and could result in a repeat repair, including installation of another generator. High resistance (caused by a damaged connector) will not go away until the damaged connector is replaced.

ACTION:
Visually inspect the harness-to-generator connector for damage (heat, corrosion, distortion and cracking) before installing a new generator. Install the Generator Wiring Harness Connector Kit (E5AZ-14305-AA) if the harness-to-generator connector is damaged.

The Generator Wiring Harness Connector Kit (E5AZ-14305-AA) contains the following:

^ One (1) Red Wire Butt Connector
^ Two (2) Yellow Wire Butt Connectors
^ One (1) Wire Connector Assembly
^ One (1) Instruction Sheet (I.S. 6849)

PART NUMBER PART NAME

E5AZ-14305-AA Generator wiring Harness Connector Kit

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 95-25-4

WARRANTY STATUS: INFORMATION ONLY

OASIS CODES: 203000, 203100, 203200, 206000