Loss of voltage, no communication between controller and voltage regulator

Your best bet would be to have a qualified repair shop diagnose the problem. Your vehicle has a smart charging system, computer controlled. Hooking up a factory or some other type of professional scan tool an checking for DTC'S - diagnostic trouble codes would be a good first step. Checking battery - cables and connections using voltage drop testing would be another good thing to do . Cables can be bad an you wouldn't be able to tell just looking at them. You might want to watch this video

Comptuter Charging Systems - Ford - YouTube

Principles of Operation
NOTE: The information contained in this section is for Escape, Mariner only. For Escape Hybrid information, refer to Section 414-03 and Section 414-05 .
This vehicle is equipped with a powertrain control module (PCM)-controlled charging system which determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. This system is unique in that it has 2 unidirectional communication lines between the PCM and the generator/regulator. Both of these communication lines are pulse-width modulated (PWM). The generator communication (GEN COM) line communicates the desired setpoint from the PCM to the voltage regulator. The generator monitor (GEN MON) line communicates the generator load and error conditions to the PCM. The third pin on the voltage regulator, the A circuit pin, is a dedicated battery voltage sense line.
The PCM uses a calibratable algorithm to estimate battery temperature and to reduce battery damage caused by over and under charging. Using this algorithm, the PCM determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator on the GEN COM circuit. While this is occurring, the PCM is also monitoring the GEN MON circuit for charging system information, such as transient electrical loads or errors.
If the PCM senses when the charging system receives a transient electrical load (which may cause poor idle quality, such as an idle roll) the PCM can then adjust the injectors opening time to account for the transient electrical load. In this manner, the PCM can maintain a consistent idle speed.
If the PCM detects a charging system error, it broadcasts a CHARGING SYSTEM STATE STATUS message through the controller area network (CAN) communication link, causing the instrument cluster to illuminate the charging system warning indicator. The charging system warning indicator is illuminated if the PCM fails to see a signal on the GEN MON circuit for a time period greater than 500 ms. This telltale is used to indicate over-voltage conditions detected by the PCM.
The PCM also reduces the mechanical load on the starter by initially commanding a low voltage setpoint (using the GEN COM circuit) in order to improve start times and reduce load on the starter and its related system.
Each time the key is cycled to the ON position, the instrument cluster initiates a bulb check by illuminating the charging system warning indicator. This operation is called prove-out. The PCM then issues a CHARGING SYSTEM STATE STATUS - OK message if the charging system is functioning properly. This message is sent once the engine is running and the charging system is determined to be operating correctly. If the cluster does not receive an OK message, the cluster lights the charging system warning indicator indefinitely. Vehicles equipped with a message center display CHECK CHARGING SYSTEM any time a charging system error is present.
This is a System 4 charging system, which uses the GEN MON and GEN COM lines to control and monitor the charging system through the PCM. System 4 charging systems are virtually identical in design and therefore, share the same diagnostics. The circuit numbers and colors may be different, but the functions are the same. System 4 charging systems may use any type of generator, as the generator type usually depends on the engine packaging and/or output requirements versus cost.

Your vehicle has a smart charging system (computer) controlled . Your best bet mite be to take it to a qualified repair shop. Have system checked for codes , full vehicle scan , not just the OBD 2 engine computer .
https://www.youtube.com/watch?v=fWu8uFj-a7E

Principles of Operation
NOTE: The information contained in this section is for Escape, Mariner only. For Escape Hybrid information, refer to Section 414-03 and Section 414-05 .
This vehicle is equipped with a powertrain control module (PCM)-controlled charging system which determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. This system is unique in that it has 2 unidirectional communication lines between the PCM and the generator/regulator. Both of these communication lines are pulse-width modulated (PWM). The generator communication (GEN COM) line communicates the desired setpoint from the PCM to the voltage regulator. The generator monitor (GEN MON) line communicates the generator load and error conditions to the PCM. The third pin on the voltage regulator, the A circuit pin, is a dedicated battery voltage sense line.
The PCM uses a calibratable algorithm to estimate battery temperature and to reduce battery damage caused by over and under charging. Using this algorithm, the PCM determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator on the GEN COM circuit. While this is occurring, the PCM is also monitoring the GEN MON circuit for charging system information, such as transient electrical loads or errors.
If the PCM senses when the charging system receives a transient electrical load (which may cause poor idle quality, such as an idle roll) the PCM can then adjust the injectors opening time to account for the transient electrical load. In this manner, the PCM can maintain a consistent idle speed.
If the PCM detects a charging system error, it broadcasts a CHARGING SYSTEM STATE STATUS message through the controller area network (CAN) communication link, causing the instrument cluster to illuminate the charging system warning indicator. The charging system warning indicator is illuminated if the PCM fails to see a signal on the GEN MON circuit for a time period greater than 500 ms. This telltale is used to indicate over-voltage conditions detected by the PCM.
The PCM also reduces the mechanical load on the starter by initially commanding a low voltage setpoint (using the GEN COM circuit) in order to improve start times and reduce load on the starter and its related system.
Each time the key is cycled to the ON position, the instrument cluster initiates a bulb check by illuminating the charging system warning indicator. This operation is called prove-out. The PCM then issues a CHARGING SYSTEM STATE STATUS - OK message if the charging system is functioning properly. This message is sent once the engine is running and the charging system is determined to be operating correctly. If the cluster does not receive an OK message, the cluster lights the charging system warning indicator indefinitely. Vehicles equipped with a message center display CHECK CHARGING SYSTEM any time a charging system error is present.
This is a System 4 charging system, which uses the GEN MON and GEN COM lines to control and monitor the charging system through the PCM. System 4 charging systems are virtually identical in design and therefore, share the same diagnostics. The circuit numbers and colors may be different, but the functions are the same. System 4 charging systems may use any type of generator, as the generator type usually depends on the engine packaging and/or output requirements versus cost.

Replace a Fuse: 2005-2007 Mercury Montego - 2005 Mercury Montego Premier 3.0L V6 https://www.carcarekiosk.com/video/2005_Mercury_Montego_Premier_3.0L_V6/fuse_engine/replace #fixeditmyself via @CarCareKiosk https://www.carcarekiosk.com/video/2005_Mercury_Montego_Premier_3.0L_V6/fuse_engine/replace

Did you test the electrical circuit's ? Have a scan tool hooked up ? Did you have a qualified repair shop check it out ?
When the engine is running, the generator control signal is sent to the generator from the engine control module (ECM)/powertrain control module (PCM), turning on the regulator. The generator's voltage regulator controls current to the rotor, thereby controlling the output voltage. The rotor current is proportional to the electrical pulse width supplied by the regulator. When the engine is started, the regulator senses generator rotation by detecting AC voltage at the stator through an internal wire. Once the engine is running, the regulator varies the field current by controlling the pulse width. This regulates the generator output voltage for proper battery charging and electrical system operation. The generator F terminal is connected internally to the voltage regulator and externally to the PCM. When the voltage regulator detects a charging system problem, it grounds this circuit to signal the PCM that a problem exists. The PCM monitors the generator field duty cycle signal circuit. The system voltage sense circuit receives B+ voltage that is Hot At All Times through the ECM/TCM fuse in the underhood junction block. This voltage is used by the regulator as the reference for system voltage control.
This vehicle uses Class II and controller area network (CAN) communications. The ECM/PCM are CAN and the body controller systems are Class II. The body control module (BCM) acts as the gateway between the different communication protocols. The ECM/PCM requests the battery lamp on the CAN communication line and then the BCM sends a request to the IPC for lamp illumination.
The ECM/PCM will request the battery lamp on under the following conditions:
• The ECM/PCM interprets the ignition is in the accessory position.
• The ECM/PCM is in the RUN power mode with the engine not running.
• Generator L terminal fault has been detected.
• Generator F terminal fault has been detected.
If the generator is not charging, it pulls the F terminal low causing an F terminal fault. Low voltage threshold is 10.5 volts for 4 minutes and engine at least 1,300 RPM. High threshold is 18 volts for 5 minutes.


https://www.motor.com/magazinepdfs/042010_09.pdf

Do you know what DTC'S diagnostic trouble codes are ?
DTC B1325
DTC B1327
DTC B1328
DTC P0562
DTC P0563
DTC P0615
DTC P0621
DTC P0622
These are all for the charging system .

Which module ?

B1318 Battery Voltage Low Audio Control Module REFER to Section 414-00 . B1318 Battery Voltage Low DSM REFER to Section 414-00 . B1318 Battery Voltage Low DVD Player REFER to Section 414-00 . B1318 Battery Voltage Low Instrument Cluster REFER to Section 414-00 . B1318 Battery Voltage Low RCM REFER to Section 414-00 . B1318 Battery Voltage Low Satellite Radio Receiver REFER to Section 414-00 . B1318 Battery Voltage Low SJB REFER to Section 414-00 .
According to this charging system isn't working correctly ! This is a computer controlled charging system .
Principles of Operation
The powertrain control module (PCM) controlled charging system determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. This system is unique in that it has 2 unidirectional communication lines between the PCM and the generator/regulator. Both of these communication lines are pulse-width modulated (PWM). The generator communication (GEN COM) line communicates the desired setpoint from the PCM to the voltage regulator. The generator monitor (GEN MON) line communicates the generator load and error conditions to the PCM. The third pin on the voltage regulator, the A circuit pin, is a dedicated battery voltage sense line.
The charging system voltage is controlled by the PCM. The generator charges the battery and at the same time supplies power for all of the electrical loads that are required. The battery is more effectively charged with a higher voltage when the battery is cold and a lower voltage when the battery is warm. The PCM is able to adjust the charging voltage according to the battery temperature by using a signal from the intake air temperature (IAT) sensor. This means the voltage setpoint is calculated by the PCM and communicated to the regulator by a communication link.
The PCM simultaneously controls and monitors the output of the generator. When the current consumption is high or the battery is discharged (the PCM recognizes this and increases the output of the generator to accommodate), the system is also able to increase the idle speed to increase the charge.
To minimize the engine drag when starting the engine, the PCM does not allow the generator to produce any output until the engine has started. The PCM then progressively increases the output of the generator.
The PCM turns the charging system warning indicator off after the engine is started and illuminates it under fault conditions (when the generator is not generating the correct amount of current with the engine running). The charging system warning indicator is also illuminated by the PCM whenever the key is ON with the engine OFF.
This is a System 4 charging system, which uses the GEN MON and GEN COM lines to control and monitor the charging system through the PCM. System 4 charging systems are virtually identical in design and therefore, share the same diagnostics. The circuit numbers and colors may be different, but the functions are the same.

Do you even know what DTC U0107 involves ?
DTC U0107
Lost Communications With Throttle Actuator Control (TAC) Module

The throttle actuator control (TAC) module and the powertrain control module (PCM) communicate via a dedicated serial data circuit. This serial data circuit is separate from any other serial data circuit on the vehicle. Accurate transmitting and receiving of serial data requires not only good circuit integrity, but also adequate system voltage. This diagnostic test monitors the accuracy of the serial data transmitted between the TAC module and the PCM. If the PCM detects a loss of data or invalid data, this DTC sets.

Diagnostic Aids
Important: Reprogramming the PCM may cause a communication error between the PCM and the TAC. If the PCM detects a communication error, DTC U0107 sets. Clear any DTCs from the memory that may have been set by Reprogramming.
• DTC U0107 sets if the battery voltage is low. If the customer's concern is slow cranking or no crank because battery voltage is low, ignore DTC U0107. Clear any DTCs from memory that may have set from the low battery voltage condition.
• DTC U0107 sets when there is a short to B+ on the TAC module ground circuit. Inspect the fuses for the circuits that are in the TAC module harness--i.e. cruise, brake. An inspection of the fuses may lead you to the circuit that is shorted to the TAC module ground circuit.
Replace the TAC module. Refer to Electronic Throttle Actuator Control Module Replacement .
Did you complete the replacement?

Hi Pattie , What relay are you jumping ? Run/crank or start relay ?
Your check engine light an passlock light are lit because there is a problem an you need to take it an have it checked out ! Unless you have a factory or equivalent scan tool ! There are DTC'S - diagnostic trouble codes stored in the BCM - body control module an in the PCM - powertrain control module . Your dealing with complex electronics an jumping things you have no clue as to how it works can render you vehicle useless !

The body control module (BCM) performs multiple body control functions. The BCM can control devices directly connected to its outputs based on input information. The BCM evaluates this information and controls certain body control systems by commanding outputs on or off. The BCM control inputs can be:
?€¢
Sensors and switches that are directly connected to the BCM

?€¢
Class 2 serial data received from other control modules connected to the class 2 serial data link.

The BCM is also capable of controlling other vehicle systems that are not directly wired to the BCM. The BCM does this by sending specific messages on the class 2 serial data link. The control module capable of performing the required function will respond to the BCM message.
The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it.
Body Control Module (BCM)
The body control module (BCM) contains the logic of the theft deterrent system. The BCM provides the 5-volt reference to operate the Passlock?"¢ sensor. The BCM also measures the voltage of the off/run/crank voltage. The voltage measured will indicate whether the Passlock?"¢ sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage to a previously learned voltage code. If the voltage codes match, the BCM sends a serial data message containing a password to the engine control module (ECM). If the voltage codes do not match, or the voltage is in the tamper range, or there is a circuit fault, the BCM will not send the correct password to the ECM, and the vehicle will not start.

check fuses 13 and 20 in the box by the battery.

it should notgo over 14 1/2 volts.

Get free DTC codes scan from Autozone. I think you will get DTC code 1246 - System Voltage Malfuction.

The I (indicator) (BAT light) wire activates alternator field circuit.

The heavy B wire circuit sends current to the battery for charing and to run the car.

The S circuit helps control the amount of charge. I suspect yours is not controlling. This car has the PCM (engine computer) help control the output and turn the BAT light on when under or over charging.

SECTION 414-00: Charging System - General Information 2003 Windstar Workshop Manual
DESCRIPTION AND OPERATION Charging System This vehicle is equipped with a powertrain control module (PCM)-controlled "smart charge" charging system. The PCM-controlled charging system is a system whereby the PCM determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. The PCM-controlled charging system is unique in that it has two uni-directional communication lines between the PCM and the generator/regulator. Both of these communication lines are pulse-width modulated. The GEN COM line communicates the desired setpoint from the PCM to the voltage regulator and the GEN MON line communicates the alternator load condition to the PCM. The third pin on the voltage regulator, the A circuit pin, is a dedicated battery voltage sense line.
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Charging system malfunction (high or low system voltage)

possible causes:

• A circuit 35 (OG/LB).
• A circuit fuse link.
• B+ circuit 36 (YE/WH).
• B+ circuit fuse links.
• Generator.
• PCM
• GEN-COM circuit 586 (RD/PK).
• GEN-MON circuit 585 (VT).

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Generator The generator (10300) on this vehicle is monitored and controlled by the powertrain control module (PCM). The PCM monitors the voltage regulator and sends a duty cycle command back to the voltage regulator to regulate the amount of field current supplied to the generator. The generator has an internal voltage regulator. The generator and voltage regulator are installed as an assembly.
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I'll send wiring diagram tomorrow.

please rate

On CRT projectors, there is a part called a focus block with adjustments for each picture tube. A sudden loss of focus is pointing to something else, a change in the high voltage. Poor high voltage regulation will cause a loss of focus. If your loss of focus has been gradual, you can try adjusting the controls on the focus block. The focus block is usually a square or rectangular block, usually mounted on the front behind a panel or on the rear behind a panel. it will have a series of red wires coming out of it. There usually are 6 adjustments on the block, 3 for screen voltages and 3 for focus. Be sure you adjusting the right ones, they are usually labeled.