Greetings! Been a while. Here’s one for the old experts!!! Reader’s Digest version: “No charge condition.” If you don’t know what a Reader’s Digest is…Google it…
I’d changed alternators or swapped diode boards in MANY an alternator on this ol’ girl and she’d been working (charging) pretty darn good for a long long time! Butt… (every one has a butt…!)…working on my old 68 XR7, which now my son is it’s caretaker, and we just ran into a charging problem tonite after firing up his new engine in the car. NO CHARGE! Hmmmmm!?
He had taken pictures and videos of everything on the starter solenoid and the voltage regulator before we yanked the engine out. Swapped engine and trans, hooked everything back up with new 408W roller cam engine and TKO 5spd, with Pertronix Distributor and old electric choke and idle solenoid from the old carb.
I fixed a ground connection on the alt harness at the head, where those wires were getting a bit frayed…same with the green/red wire at the volt regulator. I had tapped into this years ago for the electric choke/idle solenoid and it has been working great, but the connection was also showing some fraying and broke off when I pulled on it a tad…too much! So fixed that too!
Patched up a nice flexible engine coil/gauge harness for the XR7 options as well, modified slightly to put coil on front of LH head. Wired in the Pertronix distributor as well. ( would have preferred to stay with DuraSpark II, butt hey, not my car any more!)
Engine fired up ok, but had some pesky fuel leaks due to stupid new Holley with center pivot bowls that takes one of hose chrome fuel rails that puts all your fuel connections on the RH side of the engine. Get’s crowded over there and I have NEVER like those chrome rails. Hate them even more after today…
First I had tried a nice used rail…leaked like crazy out of both connections no matter how tight I wrenched…may be slowed it down… Also had a leak at the front connection from my hardline to the rail…my fault…funky flare on the line…easily fixed later.
Fast forward to getting a new fuel rail from O’Reillys. Thru it on…still gushing from the front carb fitting. Pulled it all apart, looks like the fitting in the carb is damaged perhaps from rail #1.
Dug around in my carb parts and found a brandy new (older style) bowl fitting…takes HUGE wrench and you can’t get a good grip on it unless the bowl is off of the carb. UGH! …all we have for now…
Kept tightening more…leaks…more…leaks less…MORE…dribble…EVEN MORE…now we’re tight with a spot of dribble at higher RPMS. OK…need more tight…not tonite…found I left a tiny cork spacer that goes on top of fuel filter in the bowl fitting. Will revisit tomorrow!
SO, aside from the turmoil of leaks, checking timing, adjusting idle, float levels…things were going good! Oil pressure is reading good, temp gauge is moving…alt gauge never really worked for much…but at least the alternator/battery was always charging!
Now I get 12V or battery voltage minus a few tenths of a volt.
I dug out my trusty original Ford Wiring Diagrams Book for 1968 only to run into what I believe is a known issue where Ford never added the pages for XR7’s! All of the diagrams and wiring schematics seem to be for a standard Cougar!
The date on the bottom of the page is something like 9-1-67. I have some 67 drawings as well but didn’t bother to look. I did find the Mustang pages had different wiring for the cars with gauges vs cars with idot lights. (Standard version). But for some reason, the powers that be didn’t update the XR7 features!
What was also different was the colors of the wires…usually wrong…and out of position from Standard to XR7 in the drawings.
I jumped forward to 1969 diagrams which DID have the standard drawings as well as the XR7 versions…BUTT, the wiring colors are different. They seem to go to the same places…with a few more connections in between which can get a bit dicey following the wiring.
So barring a ground that isn’t grounding or a voltage connection that isn’t crimped like it should be, I’m stumped. I will read thru the troubleshooting section of the SHOP Manual in the morning and see what I can see. Mr DVM will help check some simple conductivity issues and see what’s where if I can follow along in the book.
We’ve tried two alternators (original and one sort of new in the box! HAH!) and two regulators to no avail…leading me to think that there is a common something amiss.
Ground conductivity will be verified first, as there is now more paint than before on a few pieces and parts…but I’m thinking that the big bolts into clean aluminum, and clean o-rings on the wire ends should already be doing their job just fine…same bits that came off, went back on… and I am a competent solder iron operator!
Figured I’d ask about an updated or inclusive drawing for the XR7 folks!!! Any one?
Thanks a heap in advance!
Steve & Kevin