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If it was serviced at Ford dealership, you have GOT to suspect sabotage!
Approximately 4 months after my alternator was changed by a Blue Oval Certified Ford service center my 94 F150 began sporadically stalling at stoplights and low idle speeds. It ruined a battery before I figured out what was going on. I know from previous experiences that Ford and American law enforcement freely allow automobile sabotage to set a scam victim up for quick profit.
The set up: The Ford “technician” insisted the alternator died because a dirty battery connection overworked the alternator. He looked dumbfounded when I pointed out how clean the connectors were and the starter was spinning over normally, also with 55k miles on the truck I expected the brushes were worn out. Apparently Ford “technicians” are trained to believe in invisible corrosion that allows current to freely flow out but not into the battery.
The act of sabotage; A newly rebuild rebuilt alternator is quickly partially disassembled to allow access to the brushes. The copper connector on one of the two brushes is flexed or creased back and forth to weaken (not break) this copper brad. The road and motor vibrations will break this connection after a few hundred miles of normal driving.
The symptoms: As the copper brush brad deteriorates the alternator intermittently charges the battery. In my case the alternator warning light never came on. When the brake lights are on and the drain on the battery steals the voltage required for the ignition system and the vehicle sputters and stalls. The truck would crank, start and run with the motor revved up. The sabotaged alternator can only trickle charge the battery.
The Scam: As I understand it the “technician” will tell the victim something like, “The computer will not allow the alternator to charge.” The victim is charged for a computer replacement when all the “technician” has to do is remove the alternator, disassemble and re-crimp the copper connection on the brush. At this time he may decide to sabotage the vehicle again by flexing the other copper brad on the other brush.
I know from experience, that loosening bolt, contaminating fluids, melting electrical wiring all acceptable methods for Ford service centers to turn a quick profit! And there is nothing to stop automobile saboteurs from flexing connections or slugging tires.
Good luck
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