Connect TDCi: rubber coupling-driven alternator - WTF!?

[Nighthawk]

Even if you have a Connect with the original 1 piece wiring to the generator, if the defect was within the first foot of the loom because the little turk who built it over did it on the securing ties and they've cut through it, buy the loom and cut one plug off and join it in.

You'll have a little extra cable then to route it with out putting so much tension on it.

[Postman Pat]

Well, thanks for the pointers guys... it did indeed turn out to be a broken blue wire, apparently caused by the Turds (oops, did I spell that wrong) pulling the cable ties too tight... Five minutes with soldering iron and heatshrink, job done. The boss magnanimously suggested that Ford would probably have charged us the price of a new alternator to fix it anyway...

Now, if any of you need an x-ray system fixing, you know where to come...

[PROIL]

could you let me know where the blue wire was broken?

was it next to the connector

[coconut]

Usually about 2-3 inches back from the alternator connector

[Postman Pat]

It had actually broken just where the cable tie had crushed it against the front panel. Further along was another tie that had also crushed it; I chopped it there and spliced in a new length to be on the safe side. I'd say the crush force had 'smeared' the insulation, exposing the copper which then corroded through - it was nice and green and crusty which is the usual sign of oxidised copper.
Incidentally, returning to the 'WTF' in the thread title, what I meant was I couldn't understand why they did such a simple job as driving an alternator in such a convoluted fashion. However now I think I understand it's to do with the fancy charge control system and allowing the engine to 'over-run' the alternator so the alternator doesn't cause unnecessary drag... or summat
See, when I trained as a motor mechanic cars still had points and drum brakes...

[8skellerns]

Well, thanks for the pointers guys... it did indeed turn out to be a broken blue wire, apparently caused by the Turds (oops, did I spell that wrong) pulling the cable ties too tight... Five minutes with soldering iron and heatshrink, job done. The boss magnanimously suggested that Ford would probably have charged us the price of a new alternator to fix it anyway...

Now, if any of you need an x-ray system fixing, you know where to come...

Not anymore. Even a simple fault needs the WDS connecting so the technician has to go through the correct diagnoss procedure before concluding with the real fault. Ford did this to stop misdiagnosis. I'm sure though that it was actually changed to this way to stop misdiagnosis on warranty claims, so it saves Ford money!