Sounds more like you have a bad battery. When it is fully discharged, you'll still read 12.2 volts. To draw a good battery down to 6 volts you would have to have such a huge load on it, like a wrench dropped across the posts. I think it's more likely you weren't making good contact with the meter probes. I've been fixing tvs for 40 years, and that has happened to me all the time.
What I would try next is to get a good battery / clean the connections / or use jumper cables to get voltage on the battery cables, then measure the voltage on the output terminal on the generator. If you find 0 volts there, a fuse or a fuse link wire is burned open. The generator may be working but the current can't get back to the battery. Sometimes Ford likes to tap off that terminal to feed other circuits, and that could explain the no-crank problem.
You didn't say how the old unit failed. If it had two shorted internal diodes, that would have burned open the fuse, but if that was a fuse link wire, there would be a carbon track left behind. It's also possible for those wires to corrode and just partially open up. Either way, the strong current from the new generator trying to charge the battery would finish the job. Usually you won't smell that though.
Wednesday, January 15th, 2014 AT 5:56 PM