Ford F150 Pickup. Instruction — part 689

fasteners to specification. See TORQUE SPECIFICATIONS .

VOLTAGE REGULATOR

Removal & Installation (Except Lightning)

1. Remove generator. See GENERATOR . Remove 4 screws generator brush, terminal holder and voltage

regulator from generator.

2. To install, instructionly depress brushes, and install wire in hole to retain brushes during installation. Install

regulator and brush assembly onto generator, and remove retaining wire. Install generator in vehicle.

Removal & Installation (Lightning)

GENERATOR SPECIFICATIONS

GENERATOR SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

NOTE:

Generator brush terminal holder and voltage regulator are installed as an
assembly only.

NOTE:

Voltage regulator is integral to generator and cannot be serviced separately.
See GENERATOR .

Application

Specification

Generator Amperage Rating

4.2L, 4.6L & 5.4L

110 Amp

Lightning 5.4L SC

120 Amp

Load Test

(1)

With Tester Load

(2)

58 Amps Or More

Without Tester Load

(3)

(4)

No-Load Test

(1)(2)

13-15 Volts

(1)

All tests are performed with engine running at 2000 RPM.

(2)

All accessories off.

(3)

Perform this test with engine running, A/C on, blower motor on high speed, and headlamps on high
beam.

(4)

With accessories on, voltage should increase a minimum of 0.5 volt above base voltage.

Application

Ft. Lbs. (N.m)

Generator Mounting Bolts

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Generators & Regulators - F150 Pickup

WIRING DIAGRAMS

See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.

4.2L

35 (47)

Except 4.2L

18 (25)

INCH Lbs. (N.m)

Generator Bracket Bolts

89 (10)

Generator B+ Nut

71 (8)

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Generators & Regulators - F150 Pickup

2003 STARTING & CHARGING SYSTEMS

Starters - F150 Pickup

DESCRIPTION

The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral solenoid.
Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission Range
(DTR) sensor (A/T) or Clutch Pedal Position (CPP) switch (M/T), starter relay, and interconnecting cables and
wires.

COMPONENT LOCATIONS

COMPONENT LOCATIONS

ADJUSTMENTS

DIGITAL TRANSMISSION RANGE SENSOR

4R100 Transmission

1. Raise and support vehicle. Disconnect instruction shift control cable. Disconnect Digital Transmission Range

(DTR) sensor harness connector. Remove instruction control lever nut. Loosen DTR sensor bolts.

2. Instruction shift lever must be in Neutral. Using Transmission Range Sensor Alignment Gauge (307-351),

align DTR sensor slots. See Fig. 2 . Tighten DTR sensor bolts. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS . With instruction lever in Neutral, connect shift lever control cable.
Connect DTR sensor harness connector.

Component

Location

Battery Junction Box

Left Side Of Engine Compartment

Central Junction Box

Under Left Side Of Instrument Panel

Clutch Pedal Position Switch

On Pedal Assembly Bracket

Clutch Pedal Position Jumper

On Pedal Assembly Bracket

Digital Transmission Range Sensor

Left Side Of Transmission

Inertia Fuel Shutoff Switch

Behind Right Side Of Front Kick Panel

Starter Relay

Right Rear Of Engine Compartment

NOTE:

When battery is disconnected, vehicle computer and memory systems may lose
memory data. Driveability problems may exist until computer systems have
completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in
GENERAL INFORMATION before disconnecting battery.

NOTE:

Transmission Range Sensor Alignment Gauge (307-351) is required for this
procedure. See Fig. 1 .

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup

Fig. 1: Identifying Transmission Range Sensor Alignment Gauge (307-351)
Courtesy of FORD MOTOR CO.

Fig. 2: Aligning Digital Transmission Range Sensor (4R100)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup