I used a 5.0L E150 for reference. The stator wire is white/black, and is not used in this application.
The bigger problem is the engineers designed this system to go together quickly on the assembly line. To speed things up, they made the high-current output wire plug in instead of bolt on solidly. They knew a plug-in connection could not handle that much current, so they thought two would. As soon as a little resistance develops in one of those connections, more of the current will go through the other one and cause it to overheat. Ford specifies to never ever remove that connector with the two output wires as it will degrade the strength and tightness of the connector terminals. Replacement generators are supposed to come with a new plug already installed, and you are to splice and solder the wires to the vehicle's wiring harness. Failure to do this is less of a problem when the vehicle does not have a lot of add-on accessories and the heater fan is not used on the higher speeds often.
Sep 6, 2017 at 2:11 PM
