Painless Wiring Harness Install

[Magnolia]

Hey everyone,

I’m working through my install and I’m in the engine bay and have gotten to my alternator. I have done some research and believe I have a 3G alternator model number F794SE-29821-12V.

Some modifications have been made to the alternator and it looks like I have cables missing.

I

I’m at the point in the install where I install starter and midi fuse any suggestions?

As always thank you.

 

[904Bronco]

You are missing the field wire... Green with a red strip. It will not charge without it. You can buy a replacement plug from Napa and I am sure other auto parts stores.

 

[badandy73]

What 904 said, part lookup for a late 90's mustang/ explorer should work. Instructions for the 3G are in the painless manual, but green w/ red stripe and yellow are needed, you can clip the white w/ black stripe (middle wire).

 

[73azbronco]

If I had a do over, while I think dash out does make it easier, I also know I made a few wire runs a little tight, and I wrapped far to much. OEM bundles will wrap a tape every foot or so. I used the really neat web wrap, with tape, so what I built was tight. It resulted in some wire connections behind dash (radio, dash light) undoing over time.

 

[steelworker77]

That wiring with the green wire cut off at the plug is exactly how they come from Wildhorses. I just received one like that and called in and was told that is correct. Seems to be charging fine. See below link.

https://www.wildhorses4x4.com/early-bronco-high-output-one-wire-3g-ford-alternator

 

[904Bronco]

Good call steelworker77, Maybe Magnolia can verify if this is store bought or pulled from a vehicle in the wrecking yard?

 

[DirtDonk]

Three wires is standard 3G from the factory.
Two wires is standard “self exciting“ 3G alternator. AKA a “1-wire” alternator.
Never clip the White w/black stripe stator wire. In most cases, I can guarantee it (a3g) will not charge.
Only a 4G model alternator, such as used during an Explorer swap, use that exact same plug/connector, but do not need the stator wire.

 

[DirtDonk]

Way, you still need the large charge cable. It runs from the red insulated post that you show with the rubber cap, over to the Battery side of the starter relay.
Do you have that wire? Hard to tell from your pictures.

Is this the same alternator discussed previously? Or has it been replaced?
Do you already know that it is, or is not working? Or are you still in the middle of your install?

 

[Magnolia]

I’m still in the middle of install. I got a new plug for the alternator that has all 3 cables. I have no intentions of snipping any of the cables off the new plug.

This is the connection set up I intend to run off the alternator.


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[Magnolia]

It is the same alternator as previously discussed.

This is the setup I’m running.


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[Magnolia]

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[Magnolia]

Another question this #919 neutral safety switch. Just confuses me. I am driving a manual 3 on the tree I don’t have this connection I have circled. Do I still connect as described to the starter solenoid?

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[Magnolia]

Another question this #919 neutral safety switch. Just confuses me. I am driving a manual 3 on the tree I don’t have this connection I have circled. Do I still connect as described to the starter solenoid?

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I know I don’t have a neutral safety switch but does the painless wiring harness already have that connection installed and if so do I need to bypass it


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[DirtDonk]

What does Painless say about the manual transmission and lack of a neutral safety switch? Is there just one red with blue striped wire? Or are there two?
All that you need is for the red with blue wire to reach directly from the ignition switch to the “S” post of the starter relay/solenoid. That’s all.
So you can either find some hidden gem in the instructions (if it exists) or test the red w/blue wire with a voltmeter, test light or ohm meter between the ignition switch and the end that you can find.
Do you have battery power to it anywhere yet? Or are you not at that stage yet?
I don’t know if they include a jumper piece, or if you’re supposed to make your own, or if they already have a separate wire that goes directly to the switch without the brake for the neutral safety switch.
I’ve been meaning to reread the instructions recently, but haven’t had time.

 

[Magnolia]

I have not hooked up battery yet. I’m not quite there.

To answer my own question wire 919 is just a straight wire to ignition. So I will be mounting straight to the “S” side of starter solenoid.

I’m connecting to my coil and currently identifying if the coil is internally resisted or not and I can’t get to the part number so removing mount


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[DirtDonk]

There are ways of testing and measuring coils with an ohm meter through the different terminals.
Someone here probably knows how to do that.

Any markings on the coil that we can look at?

 

[Magnolia]

I pulled it off and it says “use with a resistance wire or external resistor” that label was unfortunately under the mount.

I need to get some ring terminals to finish off a couple connections. Then will connect battery.

To be finished off tomorrow and hopefully testing power tomorrow also.

It’s 96 degrees here so time for a break and a parts run. Thanks for your help so far. More to come


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[badandy73]

Three wires is standard 3G from the factory.
Two wires is standard “self exciting“ 3G alternator. AKA a “1-wire” alternator.
Never clip the White w/black stripe stator wire. In most cases, I can guarantee it (a3g) will not charge.
Only a 4G model alternator, such as used during an Explorer swap, use that exact same plug/connector, but do not need the stator wire

I’m still in the middle of install. I got a new plug for the alternator that has all 3 cables. I have no intentions of snipping any of the cables off the new plug.

This is the connection set up I intend to run off the alternator.


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I should've clarified in my previous post, snipping the white wire is for the explorer (4G) version, as others have mentioned.

 

[73azbronco]

If you have the opportunity, run the wire connector to the tranny tunnel with return connector to close circuit. If you ever go auto tranny, you may want it.

 

[Magnolia]

THANKS FOR THE HELP Y’ALL. I GOT HER FIRED AND RUNNING!!! I’m super stoked.

I noticed as soon as I connected my battery that my parking lights were on even with the key in my pocket. I’m gonna take a look at the switch because I also replaced that on my install. Perhaps it wasn’t all the way in the off position.


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