[dustymiller]

The dealer finally decided the problem was the alternator and replaced it. I'll get it out on the road soon and update here if the Charging System warning light returns.

Meanwhile here's the history that led to replacing the alternator:

For one, I don't think I have a smart alternator. There is no start stop function built into the van. When I first got the van, with a V monitoring gizmo plugged into the dash 12V socket, I never saw anything that suggested smart alt. I don't have anything connected to my single CCP. I do have rodent deterrent lights under the hood connected to the jump posts but that's been there a couple of years without issue. I routinely use a battery tender under the hood when parked for a while.

So I got the first "Charging System Service Now" dash light after driving away from a tire shop where I had them also replace my 4 year old battery, just due to age and winter coming on. FLA type batt.

The tire shop double checked all the connections, reset the BSM and nothing solved the problem so I had them put the old battery back in. Next I went to the dealer and got a new battery and diagnostic from them. They said the old battery tested good and the alternator tested good (spoiler alert, they changed their mind later). I had them install a new FLA battery. They reset BSM and off I go. Something from that visit caused the driver's window to stop functioning with one touch down/up.

A few days later after driving 45 minutes the warning light returned then came on about every 5 minutes. The warning light usually would usually reset itself after a few minutes even if I don't press "OK'.

The dealer said to bring it in while the warning message is showing and they'll take another look. I drove it a few more times before I took it in and could see that the warning was irregular, unpredictable timing but always came on at some point except for short errands around town.

Sometimes I'd have to drive at least 45 minutes for it to come on then it would be relentless. On the day I took it back to the dealer I left early to get in enough driving time to make sure they could pull fresh codes, which they asked for (for some reason they wanted to see it with an active warning light even though the many prior events were stored and even showing on my Ford Pass app. Why?)

The warning light came on with only 10 minutes of driving. It wouldn't stay on though and when I pulled up to the service bay it went off. Since the tech was on lunch break I kept driving it. After about 15 minutes it came back on and this time, for the first time ever, didn't reset itself. It stayed on for 25 minutes and the tech was able to get the live message in action, which they wanted.

This time they said the alternator spec allows a 0.5 volt difference between the alternator and battery (if that makes sense), and that my alternator was over producing by an additional 0.3 V and setting the warnings off. They said the alt needed replaced. That doesn't seem consistent with the fact that the dash warnings started after a tire shop put in a new battery, but after we talked some more, I OKd it for $1,600.

Had been thinking of buying a premium extended service plan but didn't yet, so I'm out of pocket for the new alternator at 58,000 miles. As an aside, now the economics of buying that ESP don't look as good.

Maybe this experience will help someone else. I'll edit this post if the warning comes back on.

 

[Functional van]

The dealer finally decided the problem was the alternator and replaced it. I'll get it out on the road soon and update here if the Charging System warning light returns.

Meanwhile here's the history that led to replacing the alternator:

For one, I don't think I have a smart alternator. There is no start stop function built into the van. When I first got the van, with a V monitoring gizmo plugged into the dash 12V socket, I never saw anything that suggested smart alt. I don't have anything connected to my single CCP. I do have rodent deterrent lights under the hood connected to the jump posts but that's been there a couple of years without issue. I routinely use a battery tender under the hood when parked for a while.

So I got the first "Charging System Service Now" dash light after driving away from a tire shop where I had them also replace my 4 year old battery, just due to age and winter coming on. FLA type batt.

The tire shop double checked all the connections, reset the BSM and nothing solved the problem so I had them put the old battery back in. Next I went to the dealer and got a new battery and diagnostic from them. They said the old battery tested good and the alternator tested good (spoiler alert, they changed their mind later). I had them install a new FLA battery. They reset BSM and off I go. Something from that visit caused the driver's window to stop functioning with one touch down/up.

A few days later after driving 45 minutes the warning light returned then came on about every 5 minutes. The warning light usually would usually reset itself after a few minutes even if I don't press "OK'.

The dealer said to bring it in while the warning message is showing and they'll take another look. I drove it a few more times before I took it in and could see that the warning was irregular, unpredictable timing but always came on at some point except for short errands around town.

Sometimes I'd have to drive at least 45 minutes for it to come on then it would be relentless. On the day I took it back to the dealer I left early to get in enough driving time to make sure they could pull fresh codes, which they asked for (for some reason they wanted to see it with an active warning light even though the many prior events were stored and even showing on my Ford Pass app. Why?)

The warning light came on with only 10 minutes of driving. It wouldn't stay on though and when I pulled up to the service bay it went off. Since the tech was on lunch break I kept driving it. After about 15 minutes it came back on and this time, for the first time ever, didn't reset itself. It stayed on for 25 minutes and the tech was able to get the live message in action, which they wanted.

This time they said the alternator spec allows a 0.5 volt difference between the alternator and battery (if that makes sense), and that my alternator was over producing by an additional 0.3 V and setting the warnings off. They said the alt needed replaced. That doesn't seem consistent with the fact that the dash warnings started after a tire shop put in a new battery, but after we talked some more, I OKd it for $1,600.

Had been thinking of buying a premium extended service plan but didn't yet, so I'm out of pocket for the new alternator at 58,000 miles. As an aside, now the economics of buying that ESP don't look as good.

Maybe this experience will help someone else. I'll edit this post if the warning comes back on.

Thanks for the heads up. I just extended the powertrain warranty on my van from 80k miles to 130k 5 years for $3,300 but that doesn't include the alternator. Price of an alternator is ridiculous. We are going to look at the GM Brightdrop van for our next build out in the next couple years. Range is 300 miles with a build out according to the builder. We bought the extended warranty on our ford because one of the turbos is leaking a bit of oil and since it's not all the time dealer would not look into it further. I think if I actually drove my van aggressively I would already have had turbo issues at 80k miles. I am still on the original front brakes and only replaced the rear brake pads preventatively as I was misinformed on brakr pad thickness making me think I needed them. I RANT...