So the original lasted almost 5 yrs, AFAYK, then replacements fail.
5 years is about the life of a battery, aint it? Did you by chance replace the battery within 6 months of the first failure?
Couple thoughts... The alternator MUST have a good source of cooling air... Has anything changed that might affect airflow? in front, over and around the alt and grill area and underneath?
Also, a spark jump between plug wires or intermediary conductor can kill a diode bank... make sure there's no way...
If you can rule out all the above, I suggest a Used Alternator... SOME actually last the life of a car.
OK, what's the scoop with the alternator/charging systems on the 98' Ford
> Windstar 3.8L V6 automatic? Anyone else been down this road and want to
> shed some light on this? I've had to replace the alternator 3 times -
> December, April and June. All alternators are from the local NAPA dealer.
> Guaranteed for life, but who can take any more of this?
>
> Symptoms =
> battery/charging light starts to flash on dash,
> alternator sounds growly when running,
> alternator so hot to the touch, after minutes, you can't get near it,
> alternator output drops to ~11v under typical load shortly thereafter,
> cabling and connectors are OK and not burnt or charred,
> connectors are dielectrically greased upon install,
> no external devices or ad-on devices of any type, no trailer, etc.
> typical load is CD player and AC...
>
> Had the van to the Ford dealer today for a charging diagnosis analysis,
> having given them the history. Bad alternator they say with no TSB's,
> reports or other known issues causing them to fail. All other possible
> things on car checked out OK. They say replace the alternator again. >
> Alternator changed today with another from NAPA because I already have $250
> into this alternator and cant afford another $250 into another from the
> local Ford Dealer. What am I missing here as well as the Ford dealer and > NAPA?
>
> Any suggestions.....I'm all ears.
>
> BLimey
>
>