Battery Cable Recall

[Electric Crow]

NHTSA: 01V031000

Been having some electrical problems and just discovered this recall. Ironically I bought mine (used) on the date notification began so I doubt she was ever checked.

Have a lot of you taken your cars in to get checked? If so is cable damage normally found?

[Y2Kat]

Auto Recall Date: FEB 06, 2001

Vehicle Component: ELECTRICAL SYSTEM:BATTERY:CABLES

Estimated Vehicles Affected: 120000

1999 Mercury Cougar Defect Summary:
VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH 2.5L V6 ENGINES. THE BATTERY CABLE WAS MISROUTED AND ITS ATTACHMENT TO THE ALTERNATOR CABLE WAS UNDER-TORQUED. IF MISROUTED, THE CABLE COULD CONTACT THE POWER STEERING LINE AND THE INSULATION COULD WEAR, RESULTING IN AN ELECTRICAL SHORT.

Defect Consequence:
THE SHORT COULD POTENTIALLY RESULT IN A FIRE, STALLING, OR A NO-START CONDITION.

Remedy:
DEALERS WILL INSPECT THE BATTERY CABLE TO THE ALTERNATOR FOR DAMAGE AND, IF IT IS DAMAGED, WILL REPLACE THE CABLE. ADDITIONALLY, THE ROUTING OF THE CABLE WILL BE CORRECTED, AS NECESSARY, AND A ROUTING CLIP WILL BE ADDED. ALSO THE TORQUE ON THE ALTERNATOR ATTACHMENT OF THE CABLE WILL BE CHECKED AND, AS REQUIRED, WILL BE TIGHTENED TO SPECIFICATION. OWNER NOTIFICATION BEGAN MARCH 22, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.

Notes: FORD MOTOR COMPANY, 01S02

[Y2Kat]

I had mine done when she still had a warranty. My problems were AFTER that. No aftermarket electrical work done yet. We installed my nitrous system and found the pos cable was shorting to something after the recall was done. It had been going on so long it was crispy. We just replaced it and went on. I didn't want to fight Fords BS storm when they screw someting up.

[Ernie]

new here, with a question. i don't know if this is the same problem, but my cougar's (99) lights, both headlights and dash lighs, have been dimming significantly especially when i brake or are idling. it starts fine and runs fine over 50 mph. anybody think it could be related to the battery cable or is it just the alternator?

[scrupul0us]

that an diff but somewhat related problem...

the dimming can is the result of insufficent amperage/voltage and as such they pulse as the alternator tries to keep up... youll find that most common cures involve:

-an upgraded negative battery cable 0-2 gauge
-an upgraded positive cable from the alt to the battery
-rewiring of the voltage sensing wire directly to the alt
(highly debated, but it does seem to work fine for most people)
-a replaced voltage regulator/clip on the actual alternator

the first three a known commonly as "the big three" which you can search for...
the later is usually the result of a car either not starting or the battery not charging...

do some searching and reading up and start a new thread with any questions/problems you may have...

i personally have done a FULL "big 3" where I ran 1 gauge from the alt to the battery with a NEW inline 175A fuse, and ran 1 gauge from the battery to the starter with a NEW inline 175A fuse... this way I bypassed ALL the stock wiring from the alt -> starter -> battery and still have the fused protection... I also installed a 2 gauge (IIRC) negative and did the voltage sensing wire hack.... that HAD to be done for me at least b/c my whole setup after new cables was pulsing HORRIBLY... the hack fixed everything... as i said though, the hack is a widely debated fix based on this one principle...

by attaching the voltage sensing wire directly to the output of the ALT, it will always READ and CALL FOR its base output, in other words, the car hasn't had a chance to put a load on the ALT and as such the ALT will give you the base AMPS its rated for

some people have found their battery wont charge or hold a charge after they have done the hack, some have no issues... i am among the ones whohad had no issues

[Tommyboy]

new here, with a question. i don't know if this is the same problem, but my cougar's (99) lights, both headlights and dash lighs, have been dimming significantly especially when i brake or are idling. it starts fine and runs fine over 50 mph. anybody think it could be related to the battery cable or is it just the alternator?

Had the same thing on the same year car.. i highly think its the alternator. Buy a volt gague and at start up check your car and see what kind of power your alternator is putting out. I dunno if you have heard or not yet, but our cars alternators are pieces of $hit! They really blow, and that same thing happened to me.. i would get it checked soon!

[Moraki]

Umm Scrump ... that is not part of the big 3. The "alt fix" is TOTALY seperate. The big three is name such because it is 3 BIG wires. The alt fix... the worst idea EVER is a small wire.

For the record the Big 3 is Alt to Starter, Starter to Battery, and the Negative Ground.

Lets not mix up good ideas and bad ideas.

[Moraki]

new here, with a question. i don't know if this is the same problem, but my cougar's (99) lights, both headlights and dash lighs, have been dimming significantly especially when i brake or are idling. it starts fine and runs fine over 50 mph. anybody think it could be related to the battery cable or is it just the alternator?

Your problem is most likely signs of the Alternator (or its internal voltage regulator) going bad. Though it could be something alterior like the sensing wire sending a bad signal to the VR or the VR plug arcing(shorting).

[99CougarNy]

where exactly does it come in contact with the power steering line? I just found my wire open and exposed but this is close to the battery ... theres a big ass black tube that comes from the front (its 11:30 out and dark as hell, i was just looking real fast to see if i saw something) .. just out of curiousity ... i'm planning on dropping in a HO alt. soon, upgrading to a 1-2 ga wire, and running a 0 ga. to the trunk where i will have a yellowtop battery. If this is ford problem, however, i'll try to work out a deal with them to run my 1 ga. wire for me or something ... who knows ... we'll see

[99CougarNy]

oh and p.s. ,my cars been having shorts, which is why this has all started ... i'll be driving and then whamm my car jerks, all electrical stops, then start back up again where the gauges recalibrate and **** ...

[Moraki]

That recall was sorta an odd ball... i havent heard many people on here who actually experienced the problem as described. Im not sure where the power steering line runs close to the battery lines. But you are definately shorting out your main power some where some how. That could be anything from a loose terminal to a loose ground going to the battery to a frayed wire grounding out.

[99CougarNy]

i'll be replacing my alt lines and modding the fuse ... i'm thinking 2 gauge alt to battery and keeping the stock wire to the starter (not having any problems with it, no sense in messing with it). I'm going to run a 0 gauge to the trunk and possible eventually get a yellowtop and remove the front battery (i'd use battery relocation terminals and place the extra "jumper" terminals in the front to bride off my fuse box and starter from there)
i'll be ordering all this stuff soon, and i'll probably end up taking pictures and doing a howto on replace the alt, running a direct line, and if i do, how to replace the fuse box cable. i think the fux box cable is going to be the most "interesting" out of all of it.