2006 4.0L stall on hot start

[RGLL]

After more reading and looking at the wiring diagrams and reading the description and operation of the alternator it is indeed controlled by the PCM but no set voltage range other than the 13.2 -15.5 value so I will replace and add new 4-gauge grounds.

 

[RGLL]

Does the fusible link come with the WC-95954 Motorcraft harness ?

 

[DieHarder]

Does the fusible link come with the WC-95954 Motorcraft harness ?

You have a 4.0, right? If so it's a different setup. You need to contact Ford for a cable replacement or perhaps someone on this forum can verify the number. When I tried to look it up the only reference I could for a 2006 V6 is: 6R3Z-14300-A but I could not find anything online. Says discontinued.

 

[DieHarder]

Does the fusible link come with the WC-95954 Motorcraft harness ?

Since you have a V6 the harness is different. In that case you can try cleaning your battery cables with baking soda. Though I would recommend a new battery harness if you can find one.

 

[RGLL]

Yes, I was not able to find a 4.0L starting and charging cable system, so I made them myself using 2 ga wire and my hydraulic terminal squeezer. I added the alternator case to mount bolt ground, the alternator mount bolt to battery terminal ground, and the engine block to motor mount ground. I replaced all of the other existing 4 ga ground and positive cables with 2 ga and also installed external star washers at each connection, and the other small gauge grounds from the PCM to radiator support were cleaned to bare metal, star washers installed and painted over with electrical lacquer paint to keep rust down. But the bottom line after these changes is I still only see 14.2 volts on my digital multimeter when running and it is the same no matter where I take the measurements. I may get a new multimeter just in case it's the meter, and I did add a digital voltmeter to the power port and to my surprise it reads .2 -.3 volts less, but it's just a cheap Amazon (Chinese) one. The service manual says that the PCM regulates the voltage to the battery based on temperature of the battery and uses IAT and an algorithm to determine battery voltage as there is no temp sensor for the battery, so hotter IAT temperatures will show less voltage and colder will be higher. But as long as they're between 13.2 -15.5 its good. Time to put some miles on it and see what happens.