Hey Guys, Today I spent the 2 hours (including beer breaks) replacing my factory 40-amp 1G with a 3G from a 95 Ford Taurus. I believe it's a 3-wire as well. It has the 3-prong ASI connector, the stator connector, and the big B+ terminal. After many hours of reading write-ups and arguments on various forums, I wired it up as such: Positive alternator terminal with new 4-gauge wire to the B+ side of solenoid (is this solenoid original? - it apparently is NOT the starter solenoid) with 175-amp Mega Fuse inline. Went ahead and put positive battery cable and starter cable (each 4-gauge) inline with the Mega Fuse as well because...why not? S wire looped right over to stator connector that's outputting 1/2 voltage. Went ahead and spliced my Holley 650 4bbl electric choke into that wire too. Green and yellow wires from A and S to the factory green and yellow wires on the other wise of the external regulator (removed). Still to do: loom all the wires, wait for actual stator connector to come in the mail (used a pinched spade connector in the meantime), figure out something better with the Mega Fuse. Does it seem like everything is connected fine? It charges fine at idle (14.5v at high idle) and so far all is well, just don't want to be damaging something long term! How does my idiot light factor into this? I've never seen it come on and I do have an aftermarket voltmeter on the dash. What's a cleaner way to do this Mega Fuse so I don't have 3 4-gauge wires hanging off of it? Also where could I find a cover to cover the 4-gauge wire on the big terminal of the alternator? The cable I bought came with a cover but it's way too big. Thanks!
The Mega fuse between battery cable and solenoid really isn't doing anything... At most it appears to be protecting starter/cable that generally isn't fused... The fuse should be between the alt and battery... OK I see it appears you have a late PMGR starter?? The charge light has a 15 ohm resistor(part of harness) across it that was also used to activate the mechanical relay, to many alts this is too much load to light the lamp(or dimly at best).... The later circuits with 2G & 3G use a 500 ohm resistor in parallel with bulb.... I cut the resistance wire at fuse box and added a 470 ohm resistor in series for my Comet, light is nice and bright...
You are absolutely right. It took some time but I figured out what my setup is. I have an aftermarket hi-torque starter so that solenoid that I thought was the actual starter solenoid really isn't. So yeah, my Mega Fuse is now just protecting a few small things coming off that solenoid. I need to move that to come off of the alternator. What does the charge light do? Tell me when it IS charging or when it is NOT charging? All I've ever had lit up on my dash is the normal back lights and that's it.
Light should be illuminated at switch on, then go off when engine starts... Of course that assumes alt is charging, if not will also be on when engine is running... With a voltmeter it isn't necessary...
