TSB 96-21-04 Generator Harness Connector
Publication Date: OCTOBER 7, 1996
FORD CARS:
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
.
.
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 (equivalent to
Standard S542)
One (1) Instruction Sheet (I.S. 6849)
PART NUMBER PART NAME
E5AZ-14305-AA Generator Wiring Harness Connector Kit
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 95-25-04
WARRANTY STATUS: INFORMATION ONLY
For other TSBs, check
here.
--------------------------------------------------------------------------------
To test the alt, first install a good CHARGED battery. Then momentarily ground the screw on the back of the alt where it says GROUND HERE TO TEST (the Field brush screw) using a jumper wire with the engine at 1500-2500RPM. Have a voltmeter connected across the battery posts. The voltage should instantly spike over 15.5V, and continue to climb slowly. Don't ground that screw for any longer than it takes to make this observation (a couple of seconds). If it fails, the fault could be in the alternator, the wiring, or any connection (including the alt to the block).
.
.
--------------------------------------------------------------------------------
TSB 98-24-06 New Electrical Terminal Grease Released for Service
Publication Date: NOVEMBER 25, 1998
FORD:
1981-1999 ESCORT
1983-1999 CROWN VICTORIA
1984-1988 EXP
1984-1994 TEMPO
1985-1999 TAURUS
1986-1997 PROBE
1988-1991 FESTIVA
1993-1999 MUSTANG
1994-1997 ASPIRE
1995-1999 CONTOUR
1996-1997 THUNDERBIRD
LINCOLN-MERCURY:
1983-1999 CONTINENTAL, GRAND MARQUIS
1984-1986 CAPRI
1984-1987 LN7
1984-1994 TOPAZ
1985-1999 SABLE
1988-1992 MARK VII
1991-1994 CAPRI
1993-1998 MARK VIII
1993-1999 TRACER
1995-1999 MYSTIQUE
1996-1997 COUGAR, TOWN CAR
1999 COUGAR
MERKUR:
1985-1988 XR4TI
1988 SCORPIO
LIGHT TRUCK:
1981-1996 BRONCO
1981-1997 F SUPER DUTY, F-250 HD, F-350
1981-1999 ECONOLINE, F-150, F-250 LD
1983-1999 RANGER
1984-1990 BRONCO II
1984-1997 AEROSTAR
1991-1999 EXPLORER
1993-1999 VILLAGER
1995-1999 WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER
1998-1999 NAVIGATOR
1999 SUPER DUTY F SERIES
MEDIUM/HEAVY TRUCK:
1984-1999 F & B SERIES
1988-1997 CARGO SERIES
1996-1998 AEROMAX, LOUISVILLE
ISSUE: Ford Motor Company has released a new Electrical Grease (F8AZ-19G208-AA) to reduce the possibility of moisture corrosion at the terminals.
XG-12 Electrical Grease (F8AZ-19G208-AA)
ACTION: Add the new grease during electrical connection repair.
CAUTION: ELECTRICAL CONNECTOR GREASE SHOULD NOT BE USED IN HIGH VOLTAGE CONNECTIONS FOR SPARK PLUG AND COIL WIRE APPLICATIONS.
PROPER USES OF THE NEW ELECTRICAL GREASE INCLUDE:
Electrical Connectors
Battery Connections
Light Sockets
Starter Terminals
DO NOT USE ON:
Spark Plug Wires
Coil Wires
Spark Plug-to-Coil Connections
Low Current Flow Switches (12V Systems less than 0.1 amp)
DO NOT CONFUSE WITH
XG-3A Silicone Brake Caliper Grease And Dielectric Compound (D7AZ-19A331-A)
![alternator-130a.jpg TSB 96-21-04 Generator Harness Connector
Publication Date: OCTOBER 7, 1996
FORD CARS:
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
[url=https://www.supermotors.net/registry/media/910523][img]https://www.supermotors.net/getfile/910523/thumbnail/altwiring2g3g.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/899496][img]https://www.supermotors.net/getfile/899496/thumbnail/92f2g.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/843760][img]https://www.supermotors.net/getfile/843760/thumbnail/alternator2gex.jpg[/img][/url]
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 (equivalent to [url=https://www.amazon.com/dp/B000C7ZVO6]Standard S542[/url])
One (1) Instruction Sheet (I.S. 6849)
PART NUMBER PART NAME
E5AZ-14305-AA Generator Wiring Harness Connector Kit
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 95-25-04
WARRANTY STATUS: INFORMATION ONLY
For other TSBs, check [url=http://www.revbase.com/BBBMotor/]here[/url].
--------------------------------------------------------------------------------
To test the alt, first install a good CHARGED battery. Then momentarily ground the screw on the back of the alt where it says GROUND HERE TO TEST (the Field brush screw) using a jumper wire with the engine at 1500-2500RPM. Have a voltmeter connected across the battery posts. The voltage should instantly spike over 15.5V, and continue to climb slowly. Don't ground that screw for any longer than it takes to make this observation (a couple of seconds). If it fails, the fault could be in the alternator, the wiring, or any connection (including the alt to the block).
[url=https://www.supermotors.net/registry/media/843907][img]https://www.supermotors.net/getfile/843907/thumbnail/alternator3gvr.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/1079023][img]https://www.supermotors.net/getfile/1079023/thumbnail/3gs.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/144060][img]https://www.supermotors.net/getfile/144060/thumbnail/alternator-130a.jpg[/img][/url]
--------------------------------------------------------------------------------
TSB 98-24-06 New Electrical Terminal Grease Released for Service
Publication Date: NOVEMBER 25, 1998
FORD:
1981-1999 ESCORT
1983-1999 CROWN VICTORIA
1984-1988 EXP
1984-1994 TEMPO
1985-1999 TAURUS
1986-1997 PROBE
1988-1991 FESTIVA
1993-1999 MUSTANG
1994-1997 ASPIRE
1995-1999 CONTOUR
1996-1997 THUNDERBIRD
LINCOLN-MERCURY:
1983-1999 CONTINENTAL, GRAND MARQUIS
1984-1986 CAPRI
1984-1987 LN7
1984-1994 TOPAZ
1985-1999 SABLE
1988-1992 MARK VII
1991-1994 CAPRI
1993-1998 MARK VIII
1993-1999 TRACER
1995-1999 MYSTIQUE
1996-1997 COUGAR, TOWN CAR
1999 COUGAR
MERKUR:
1985-1988 XR4TI
1988 SCORPIO
LIGHT TRUCK:
1981-1996 BRONCO
1981-1997 F SUPER DUTY, F-250 HD, F-350
1981-1999 ECONOLINE, F-150, F-250 LD
1983-1999 RANGER
1984-1990 BRONCO II
1984-1997 AEROSTAR
1991-1999 EXPLORER
1993-1999 VILLAGER
1995-1999 WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER
1998-1999 NAVIGATOR
1999 SUPER DUTY F SERIES
MEDIUM/HEAVY TRUCK:
1984-1999 F & B SERIES
1988-1997 CARGO SERIES
1996-1998 AEROMAX, LOUISVILLE
ISSUE: Ford Motor Company has released a new Electrical Grease (F8AZ-19G208-AA) to reduce the possibility of moisture corrosion at the terminals.
[url=http://www.fcsdchemicalsandlubricants.com/Products/Details?cid=50&pid=291]XG-12 Electrical Grease (F8AZ-19G208-AA)
[img]http://www.fcsdchemicalsandlubricants.com/images/Products/XG12.jpg[/img][/url]
ACTION: Add the new grease during electrical connection repair.
CAUTION: ELECTRICAL CONNECTOR GREASE SHOULD NOT BE USED IN HIGH VOLTAGE CONNECTIONS FOR SPARK PLUG AND COIL WIRE APPLICATIONS.
PROPER USES OF THE NEW ELECTRICAL GREASE INCLUDE:
Electrical Connectors
Battery Connections
Light Sockets
Starter Terminals
DO NOT USE ON:
Spark Plug Wires
Coil Wires
Spark Plug-to-Coil Connections
Low Current Flow Switches (12V Systems less than 0.1 amp)
[url=https://www.supermotors.net/registry/media/825375][img]https://www.supermotors.net/getfile/825375/thumbnail/alternatormountboss.jpg[/img][/url]
DO NOT CONFUSE WITH [url=http://www.fcsdchemicalsandlubricants.com/Products/Details?cid=50&pid=446]XG-3A Silicone Brake Caliper Grease And Dielectric Compound (D7AZ-19A331-A)
[img]http://www.fcsdchemicalsandlubricants.com/images/Products/XG3A.jpg[/img][/url]](https://www.supermotors.net/getfile/723349/fullsize/alternator-130a.jpg)