This 2003 Ford Expedition came in with the complaint that the alternator had been replaced twice and the charge light light indicator was still coming on. The shop that had installed the alternators had called in desperation as their customer was becoming quite upset. They also stated that the light may stay out all day or only about an hour. When their customer showed up with the vehicle I was a little surprised. The shop usually sends vehicle on a flat bed and drops them off. Time to try and make everybody happy (except Me) while the customer waits(I was trying to eat lunch). I did a quick visual inspection of the wiring at the alternator and everything looked okay. I checked codes and found a code P0620 stored (alternator problem). I then looked at the wiring leading to the alternator and I saw this telltale sign. A wire with discoloration against a metal object.
The metal object in this case was the a/c low pressure or suction line that runs along the lower edge of the battery. I lifted the wiring up and could tell from the amount of discoloration that I might have found the problem.
Yep there’s the problem. I removed some more tape. Wrapped the damaged wire. Rewrapped the harness.
Installed some split loom and cleared the codes. Rechecked the system and all was okay. Back to my lunch.
So, two months later still have the check charging system warning. On reccomendation from the dealer changed the harness from the alternator to the battery. (same one that was frayed in the picture) 40 bucks. Had a friend re flash the computer with latest software and still no good. Still driving around with the light on. It comes on 25 seconds or so after the engine is started. Otherwise it drives fine but it is annoying having that light on and not knowing why. Any other suggestions? Alternator putting out 13.9 volts and battery checks good.
Disconnecting the battery will usually clear the codes. A scan tool is preferred though.
OH MAN! Could this be it? I changed the alternator yesterday (luckily still under warranty) of course still had the red battery light and the “check charging system” message on the dash of my 03 EB. I noticed this wire laying over that ac tube and thought that it could be bad but kind of forgot about it at the time. I will be checking this wire for damage first thing in the morning hoping to show my wife how smart I am! By the way, is there a way to clear the codes with out a diagnostic tool or can auto zone do this with thiers?
I have been dealing with this same problem for my 03 EB Expedition and have spent hours of labor trying to find the problem. After reading this post I discovered that mine has this same problem and after wrapping the wiring the problem was fixed. Thank You!!!
I am so thankful you posted this. After doing hours of research on what this problem might be, I was lucky enough to stumble upon this site and sure enough, this was my problem. I had my boyfriend fix it in 10 minutes and I saved a ton of headache and money. Thank u thank u thank u!!!