Power Drain on 2000 petrol mini bus

[nifty]

Hi, I am based in Cairns, Australia (in case hot weather makes a difference!) My early 2000 model Transit mini bus experienced a power drain which led to guages dropping to zero, engine failure and sitting on the side of the road. A few hours later you could start it again and it would last another day or so. Over a month or two the power drain became worse and now the battery light will not go out even with a freshly charged battery. My local Ford dealer says the vehicle is too old to put on their computer and suggested new plugs, leads and coils. I have replaced all of these. Another Transit owner suggested a new starter motor? I have also replaced the alternator. The bus is a 2litre petrol model. This little bus is my work-horse for small jobs and I have had it since new. It has travelled 308000klms. Can anyone help me please?

[ake]

Checks main battery lead and connections for damage, check fuses next to battery for damage, check battery output when running and stopped

[nifty]

Sorry to take so long getting back to you. Cables all appear fine and connections at either end are tight. Long narrow fuse box beside battery is fine, as are the 4 fuses inside. About the only thing I can remember touching on the vehicle around the time this started was replacing a headlight! I do remember that replacing the alternator seemed to fix the problem for about 3 or 4 days. I'm stuck.

[nifty]

Also forgot to mention, battery output when stopped is 12.31, when running is 11.38.

[hornhead]

should be 13.8 when running

check ign light bulb and connections back to Alt at it can't charge withot reference voltage

[nifty]

I'm afraid you're going to have to "dumb it down" as the Yanks would say. I ripped out the instrument panel and instantly panicked! Where is the ignition light? Which one is it? Some of the wires registered a reading around 11.25 and some registered nothing. I don't have a clue where they go anyway so all I did was amuse myself and a few Indian Minor birds. I think I'm due yet another trip to an auto electrician - at least this time armed with your suggestions. Maybe they can put the instrument panel back in for me.

[ake]

All you need to do is turn on the key till the lights come on, but dont start it, is there a picture of a battery This is ignition lamp

[nifty]

yes, this is the light that never goes out.

[Altransit]

yes, this is the light that never goes out.

Does it come on when the ignition is on, but no engine running

[nifty]

Yes. It drops in brightness as the engine starts then remains dim while engine is running.

[Altransit]

Well, that can only be an alternator problem as far as I can see .......... was it a new one?
Sounds like the diode pack is faulty

[nifty]

Actually it is a reconditioned one but has been checked by two auto electricians who say its good. There was that improvement for a few days after it was installed, but I wrote that off as just being a fresh charge in the battery which ran down over that time. Even Ford said it was ok.

[ake]

Check the connection on the back of the alternator are all clean and tight, failing that I'm with Altransit

[Altransit]

Actually it is a reconditioned one but has been checked by two auto electricians who say its good. There was that improvement for a few days after it was installed, but I wrote that off as just being a fresh charge in the battery which ran down over that time. Even Ford said it was ok.

Also forgot to mention, battery output when stopped is 12.31, when running is 11.38.

How did they come to the conclusion that the alternator was OK when your reading is less than battery voltage
The running voltage from the alternator should be anything from 13v up to 14.5v, depending on the state of the battery and any electrics which are demanding current at the same time.
So the alternator can't be working correctly. or (less likely!) you have a MASSIVE power drain going on somewhere which exceeds the alternator output!!

[nifty]

Damn good point there my friend. I'll get that checked out and let you know. By the way Ake, I've read quite a few of the questions and replies on this forum while waiting for the rotten 10 hour time difference, and I've got to say you blokes do a damn good job. Friendly and helpful - even if I don't solve my problem - it's nice to be a part of. Good work and keep it up.
Thanks