Muddy water fording alternator issue fix: TSB 22-2392 -- Mud Accumulation in Generator

[Hopeless Diamond]

yeah, I couldn't find a belt so had to take it off and reuse. That was one of the biggest hassles.

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[Gilligans_off]

So apparently when I killed the alternator in the mud, it also wiped out 2 or more pulleys says the Tech note. The alternator was covered under warranty but the pulleys won’t be ffs

They want to replace the three idler pulleys and the tensioner. When I asked why they don’t just replace the ones that failed instead of all 4, the advisor looked at me I was in the wrong and started humming and hawing. Guess it’s too much work to diagnose properly. Ford said they couldn’t reverse the judgment due to the Dealership saying it had too much water/mud to be warranty eligible.

 

[Hopeless Diamond]

Is this a 2.3? There aren't any idlers for the alternator on the 2.7, it uses a stretch belt. Guess the crank pulley and other systems could have been damaged, but that's way more than what the TSB would cover

 

[Razorbak86]

just want to make sure If there is something wrong with Bronco alternator, with TSB, should all repairs be covered by the warranty?
After checking my alternator, the dealer said that the problems caused by the rocks, grass twigs inside were not caused by mud, and were not covered by the warranty. Then I took out the TSB to them, and now the dealer said that they are finding solutions to see how to solve it.

not sure how you got twigs inside of the housing, but bet you had fun doing it .

If you don’t have twigs in your mud, you’re doing it wrong.

Besides, why just take a bath with water when you can enjoy a real mud spa?!?

 

[Gilligans_off]

Is this a 2.3? There aren't any idlers for the alternator on the 2.7, it uses a stretch belt. Guess the crank pulley and other systems could have been damaged, but that's way more than what the TSB would cover

2.7 on the accessory side belt

wasn’t part or the TSB but it all happened during the same incident that caused the alternator failure. Has sure shaken my confidence on the trails that’s for sure.

 

[LanceIto]

Great thread. Surprised the TSB exists!!! The O&M manual specifically states maximum speed through water crossing is 4 mph. I assume Ford would say sorry you exceeded the design conditions.

My Jeep buddies bust my b@lls severely because of the 4 mph max. They take videos every time I slowly crawl through a deep creek crossing.

 

[redone17]

Ha! I never noticed that 4 mph clause. Doesn’t that go against all real world experience in that you need to keep a brisk and steady pace through mud? 4 mph is sloooooooow.

 

[Jazer]

Does the alternator have to come all the way out to install the shield? Thinking about installing it preemptively.

 

[msujay2012]

Does the alternator have to come all the way out to install the shield? Thinking about installing it preemptively.

Thinking of doing the same since I wheel in muddy areas. Here is what I found.
https://www.levittownfordparts.com/docs/MB3710317J.pdf

 

[evilletruck]

Does the alternator have to come all the way out to install the shield? Thinking about installing it preemptively.

unfortunately yes

 

[Jim Walter]

I would think a dealer could order the shield before a failure will occur. The TSB seems to indicate that the shield and generator will be replaced in the event of failure. I don't think there is any issue or redesign with the generator. @flip might be able to weigh in on the issue.

I ordered one from the dealer. Took less than a week to get. Will schedule the install at my next oil change.

 

[mrjking2000]

The real question is why did ford put the alternator at the bottom of the motor lol! while I love this thing, the alternator should have been near the top like many other "offroad" vehicles i've owned.

 

[Valhalla]

note: I run 37's off-highway... I don't often "hit" mudholes. I do however ford mud that exceeds the recommended depth.... enter slowly and continuously lightly increase throttle as you cross to push a wake and not submerge you vehicle. I know getting a "MUD TROPHY" is fun. However mud is corrosive... If you don't spend a day pressure washing underneath you are killing your toy.

This was day four of owning it.

 

[Night Horse]

I'm curious to know how many of you with the newer alternator shield have experienced a failure? (2023+ models or if the shield was added later)

 

[Rickbobby334]

I knew exactly what I did to kill mine when I got that message the day after, and it was fun killing it!

Hate to have to chime in now, but I am going through this issue right now. Finally getting to this source of information on the issue. Light has been on for 2 weeks, after troubleshooting all possible issues. Now the battery is dying and the local ford dealership in Poland are not authorized to service American spec Bronco’s. WTH Now I must get it to Berlin. 3 hour drive or transport?????

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