Bostig - OXS and Battery Light flickering

[Captjon1959]

I did a Bostig conversion a couple years ago and love it. On my last trip I noticed the van was occasionally hesitating when I was cruising at 70 mph. Then I notice the OXS and Battery light would flicker and the tach would drop to zero and bounce back up. As time went on it became more frequent so I turned around and headed home.

Here's the facts:
- '84 full camper
- Bostig Zetec - with pre-programmed chip)
- 0ld Battery
- Used alternator (Ford Contour)
- GoWesty leisure battery set up
- added fuse box and wiring for interior lights

I searched the forum here and it confirmed what I thought might be the problem - failing alternator (floating brushes), bad belt (slipping).

So I replace the alternator, the battery, and the belt. The van started much better with the new battery and the belt definitely needed to be replaced.

Took it on the road. Up to 40 mph no problem. As I reach highway speed the lights start flickering, but no hesitation or jumping tach. I noticed that the flickering was associated with higher rpm (just before the automatic shifts) and when I put it under load (like accelerating).

So, it doesn't seem to be floating brushes at high rpm and it shouldn't be the belt. I wondered about the belt tensioner, but it seems to be working to me. I used my Torque program to see if the OBD2 showed any fault codes and it doesn't.

Any ideas? Bostig says it might be a wiring issue, but my electrical problem solving skills are lacking. I appreciate any suggestions.
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1984 Westfalia Wolfsburg Edition
Former 1.9 L now Bostig Ford Zetec

[JudoJeff]

Clean and check all grounds.

Look for loose wires on the fuse block. Gently yank/pull on everything.

You can buy a cheap device that plugs into your cigarette lighter at Harbor Freight, and the LEDs will light up to tell you what's working, battery and alternator.

Doesn't sound major, but something is loose.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[Captjon1959]

I need some more input and/or ideas. I checked wires at the fuse block by wiggling them. I removed the ground in the engine and regrounded it. I looked for damaged wires or connections. It seemed better but then started flickering again and cutting out. Today on the highway the tach would drop out and the van would hesitate without the lights flickering. It sure seems electrical, but I can't isolate it. What is the right diagnostic approach for a guy who isn't experienced with automotive electronics. Thanks.
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1984 Westfalia Wolfsburg Edition
Former 1.9 L now Bostig Ford Zetec

[alnvilma]

"Cutting out..."
Maybe your ignition switch. The OX light is irrelevant.

[Captjon1959]

I wondered about the ignition switch too. I replaced it a couple years ago, but had the whole dash apart last winter to replace the front blower... maybe I pinched a wire. I have an automatic and also replaced the neutral position switch. I will check those two items. Thanks.
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1984 Westfalia Wolfsburg Edition
Former 1.9 L now Bostig Ford Zetec

[JudoJeff]

Replace the coil on the zetec. Might be cracked and cutting out at the higher rpms. Cost is about $25 on Ebay.

Look at your plugs wires, too, those are also cheap to replace.
_________________
________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)