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Old 02-10-2018, 11:04 AM
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Clutched alternator issue... (?)

I don't spend a lot of time driving my Merc. She sits for months with no issues when it's time to turn that key. Recently I have noticed the battery dead or extremely weak and after a full charge (Motorcraft Maxx BXT 65-750) the battery tested ok. Took the car to work Friday and drove home without incident. Noticed last night with headlights and A/C the voltage drops to 10 with brake application at idle. The system reads 13.8 - 14.1 at idle with NO load (13.8 - 14.4 is norm). I am gonna remove the alternator and have it tested. I noticed the pulley clutch is locked and spins the stator in both directions. Is there a possibility the clutch may be slipping in the drive direction? I am familiar with the way these work but can they fail and allow slippage under load? I am having the alternator rebuilt and the clutch replaced but with 49K miles an alternator failure seems unlikely. Any opinions on this?
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'04 Silver Marauder w/ sunroof - HID lighting, JL Audio / Eclipse DVD/NAV/iPod/camera, 4.10's, 2" drop, Progard, Delete tips, Billet Pedals, BC4E dead pedal, Lidio Tune, Innovative chin spoiler, K&N CAI, TCE SS lines, Super40's, tinted tails, SS Inserts, Heinous Control Arms, Real oil gauge, Steeda UDP.

2004 Mercury Marauder
Born March 2004, adopted October 2005. Sold January 2012, adopted AGAIN January 2016
#2,187 of 3,214
997 in Silver Birch
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  #2  
Old 02-10-2018, 06:20 PM
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The alternator tests fine. The clutch is seized. I didn't realize these require a special tool that gets used one time. This still doesn't explain the loss of charging power so it looks like a local rebuild since it's out anyway.
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'04 Silver Marauder w/ sunroof - HID lighting, JL Audio / Eclipse DVD/NAV/iPod/camera, 4.10's, 2" drop, Progard, Delete tips, Billet Pedals, BC4E dead pedal, Lidio Tune, Innovative chin spoiler, K&N CAI, TCE SS lines, Super40's, tinted tails, SS Inserts, Heinous Control Arms, Real oil gauge, Steeda UDP.

2004 Mercury Marauder
Born March 2004, adopted October 2005. Sold January 2012, adopted AGAIN January 2016
#2,187 of 3,214
997 in Silver Birch
448 with light flint interior
304 with heated seats
336 with sunroof
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Old 02-10-2018, 09:28 PM
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Itís the same tool used for VW, Audi, and a ton of German cars. I picked one up on EBay for like $6.


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Cobra short block / ProCharger F1-A / Cog drive upgrade / Manley valves / Brian Tooley Racing valve springs / 80# inj. / -8 fuel line / -6 return / Aeromotive 340 pumps and regulator / 2012 GT500 TR6060 six speed / twin disc clutch / Driveshaft Shop GT500 upgraded CV joint shaft / BA5000 blow thru MAF/ 4.10's / Ford Racing 31 spline set up and Girdle / Metco D.S. safety loop / Stainless Works headers, cats, and everything else out back / ClassGlass hood / Bob's hood strut mod / Hurst line lock / Metco control arms / Addco front and rear sway bars / Monroe severe duty shocks all around / Race concepts rotors / Badgeless grille / 35% tint / FBM's interior LED kit and ambient lighting kit / Pioneer FB700 deck / kenwood speaker 4 Ch. / Rockford Fosgate 10" sub and amp / Kicker 6 X 8's all around / back up cam / bluetooth / Pioneer Xm / 704 RWHP 603 RWTQ tuned by Mo's Speedshop.
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Old 02-11-2018, 09:04 AM
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Excellent! Thank you for that because the Gates complete kit is in the $100 ballpark. I checked to make sure my harmonic isn't slipping. Even with the underdrive I raised the idle ~200rpm a decade ago and had no charging problem. This is the first puzzling issue I have had. Just bought this! https://www.ebay.com/itm/33-Spline-A...EAAOSwc6JaaECQ
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'04 Silver Marauder w/ sunroof - HID lighting, JL Audio / Eclipse DVD/NAV/iPod/camera, 4.10's, 2" drop, Progard, Delete tips, Billet Pedals, BC4E dead pedal, Lidio Tune, Innovative chin spoiler, K&N CAI, TCE SS lines, Super40's, tinted tails, SS Inserts, Heinous Control Arms, Real oil gauge, Steeda UDP.

2004 Mercury Marauder
Born March 2004, adopted October 2005. Sold January 2012, adopted AGAIN January 2016
#2,187 of 3,214
997 in Silver Birch
448 with light flint interior
304 with heated seats
336 with sunroof
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  #5  
Old 02-11-2018, 04:02 PM
camaro_dude15 camaro_dude15 is offline
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parts store experience says the Chrysler pulleys will fail in such a way that will allow it to slip in the drive direction cant say the say the same for the mm clutches as i have never had to sell one or even test one
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Old 02-11-2018, 05:33 PM
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Quote:
Originally Posted by camaro_dude15 View Post
parts store experience says the Chrysler pulleys will fail in such a way that will allow it to slip in the drive direction cant say the say the same for the mm clutches as i have never had to sell one or even test one

Knowing that and knowing mine is not working properly I will replace the clutch first and see if that alleviates the voltage issue. Thank you for letting me know because this may very well be a similar issue.
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'04 Silver Marauder w/ sunroof - HID lighting, JL Audio / Eclipse DVD/NAV/iPod/camera, 4.10's, 2" drop, Progard, Delete tips, Billet Pedals, BC4E dead pedal, Lidio Tune, Innovative chin spoiler, K&N CAI, TCE SS lines, Super40's, tinted tails, SS Inserts, Heinous Control Arms, Real oil gauge, Steeda UDP.

2004 Mercury Marauder
Born March 2004, adopted October 2005. Sold January 2012, adopted AGAIN January 2016
#2,187 of 3,214
997 in Silver Birch
448 with light flint interior
304 with heated seats
336 with sunroof
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  #7  
Old 02-11-2018, 08:15 PM
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justbob justbob is offline
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Quote:
Originally Posted by BAD MERC View Post
Excellent! Thank you for that because the Gates complete kit is in the $100 ballpark. I checked to make sure my harmonic isn't slipping. Even with the underdrive I raised the idle ~200rpm a decade ago and had no charging problem. This is the first puzzling issue I have had. Just bought this! https://www.ebay.com/itm/33-Spline-A...EAAOSwc6JaaECQ


Thatís the one!


Sent from my iPhone using Tapatalk
__________________


Cobra short block / ProCharger F1-A / Cog drive upgrade / Manley valves / Brian Tooley Racing valve springs / 80# inj. / -8 fuel line / -6 return / Aeromotive 340 pumps and regulator / 2012 GT500 TR6060 six speed / twin disc clutch / Driveshaft Shop GT500 upgraded CV joint shaft / BA5000 blow thru MAF/ 4.10's / Ford Racing 31 spline set up and Girdle / Metco D.S. safety loop / Stainless Works headers, cats, and everything else out back / ClassGlass hood / Bob's hood strut mod / Hurst line lock / Metco control arms / Addco front and rear sway bars / Monroe severe duty shocks all around / Race concepts rotors / Badgeless grille / 35% tint / FBM's interior LED kit and ambient lighting kit / Pioneer FB700 deck / kenwood speaker 4 Ch. / Rockford Fosgate 10" sub and amp / Kicker 6 X 8's all around / back up cam / bluetooth / Pioneer Xm / 704 RWHP 603 RWTQ tuned by Mo's Speedshop.
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  #8  
Old 02-11-2018, 10:47 PM
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Just buy a non clutch pulley. You will need one for a eaton swap anyway.

I bought my clutch tool on ebay for 5-6 bucks too!
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Old 02-12-2018, 12:03 AM
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Interested to hear the follow-up. Please let us know.
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2003 300A Black, #4918 of 7838, 17,400 Miles
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2003 300B Silver Birch, #21 of 419, 29,800 miles
Tune, JLT, FlowMaster 42441 Res Delete, New Nitto 235/255 Bigcarsforever dead peddle & custom SRP peddles, 5 coats Zymoil Titanium, Addco front and rear sway bars, KYBs, 1/2 inch coil cut, Sparts Watts link and Control Arms, Car fixer alignment.
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  #10  
Old 02-12-2018, 05:55 PM
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BAD MERC BAD MERC is offline
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Quote:
Originally Posted by 1Marauder View Post
Interested to hear the follow-up. Please let us know.
Carfixer (Claude) is my neighbor and we were discussing it, too. He suggested doing a solid pulley swap first. Dorman makes a replacement clutch pulley but it's in the $75 range. A replacement alternator WITH pulley is $135.

I have a sneaking suspicion it may be slipping on the drive side at high RPM's. Plus it is 14 years old and has been powering 800 watts of amplifiers for the same amount of time.


Follow-up after a few different things are tried.
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'04 Silver Marauder w/ sunroof - HID lighting, JL Audio / Eclipse DVD/NAV/iPod/camera, 4.10's, 2" drop, Progard, Delete tips, Billet Pedals, BC4E dead pedal, Lidio Tune, Innovative chin spoiler, K&N CAI, TCE SS lines, Super40's, tinted tails, SS Inserts, Heinous Control Arms, Real oil gauge, Steeda UDP.

2004 Mercury Marauder
Born March 2004, adopted October 2005. Sold January 2012, adopted AGAIN January 2016
#2,187 of 3,214
997 in Silver Birch
448 with light flint interior
304 with heated seats
336 with sunroof
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  #11  
Old 02-12-2018, 09:01 PM
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Turbov6Bryan Turbov6Bryan is offline
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Pull the brush pack off, is one brush stuck or worn out? When my alt stopped working, one of the brushes was done.

Its just a few screws 4 to pull the bracket, and i think 2 more for the brush pack. I dont think the pulley is the issue (ya never know), you can get the pulley for free at a bone yard.

Also the MGM has the clutch too..

Let us know.

PS/ I think its funny is nobody really talks much about the alt here, i was wondering if the cop car 200 amp with our PWM regulator bolted on to it would make it work. IDK... too many irons in the fire at the moment. But that would be cool if we could get a cop car one, and bolt our regulator on it and have a simple mod swap for our cars thats ford proven. Aftermarket and reman can suck my left one
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