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REPORT NUMBER - FORBA02410 MAKE FORD | MODEL BA YEAR 2002 | ENGINE 6 cylinder
Customer Complaint Fitted a replacement alternator but warning light not going out..
Problem Summary
A new alternator had been fitted, but the warning light remained on, and it was overcharging.
Diagnostic Sequence
Incorrect alternator for application.
In the Ford AU and BA there is a subtle difference in the two alternators.
Visually they both look the same but the internal regulator works differently.
Fault Description
The difference is found in the voltage regulators these alternators use.
The AU alternator is a battery-sense type and uses a regulator that requires both a sense (S) and lamp (L) connections. The BA alternator is a machine (internal)
sense type and uses a regulator that only requires a lamp (L) connection.
A problem will occur if an AU regulator is used when servicing the BA alternator.
The wiring loom in the BA does not provide a battery-sense positive signal in the sense lead to the alternator (even though it is in the harness from the alternator up to the plug connector at fuse box).
In this case the warning light will stay on and a higher regulating voltage will be observed.
Fault Solution The solution to this problem is not difficultand a slight modification is easy to carry out.
All that is required is to give the (S) circuit a positive voltage supply.
This can be done in many ways.
Here is one way we have found to be quick, neat and easy. At the BA main fuse box under the bonnet you will see a 4 pin connector with 4 wires, just unplug it and you will see that there is one pin missing in the base of the plug. That is the missing (S) circuit.
Just solder a wire to the thick yellow/white wire and lug the other end and bolt it to main positive stud on the side.
Recommended Time
Labour time was .5 hours, taking into account research time, location of partsand actualtime spent fixing the problem.
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with 4 wires, just unplug it and you will see that there is one pin missing in the base of the plug. 
That is the missing (S) circuit.
and lug the other end and bolt it to main positive stud on the side.
