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Unread 05-01-2013, 06:25 AM   #1
Double E
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Fixed alternator with hammer, what next? (4.7)

Just turned over 170K.

On a recent 3 hour trip, my alt reading kept going lower & lower to the point that the check gauges light came on.

Knowing the alternator was suspect, I pulled over & left the engine running.

I tightened the batt cables to make sure it was pulling all juice it could to keep running & gave a whack to the top of alternator out of frustration with a tire iron.

It instantly "righted" itself and the engine RPMs increased and the under hood light brightened. Inside, the alt needle was back to just under 14 and it stayed that way for the rest of the trip.

On the way back home, 2 days later it did the same thing and I fixed it again the same way.

My question: Is that "fix" I found a classic sign of the alt going bad or is there something else recommended like opening it up and cleaning it out.

Is there a re-build kit recommended or is a newe one the only option?

Replace the belt while I'm in there, right?

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2000 Laredo 4.7L Selec-Trac. 177K miles, Leather, 245 tires, tow package, crappy CD changer, full size spare, roof cross-rails & sunroof.
Changes & fixes: Rear Addco sway bar & greasble bushings, upgraded headlights, upgraded tail lights, new hood struts (replaced 2X), new rear hatchglass struts, new radiator (replaced 3X), new oil pressure sending unit (replaced 4X), 2 new speed sensors, 2 new door lock actuators, new ignition key cylinder, chrome front tow hooks, Mobil 1 Synthetic 5/30, Purolator Pure One oil filter, EBC slotted & dimpled rotors, EBC Greenstuff pads, new front shocks (replaced 3X), new rear shocks (replaced 2X), new IRO steering stabilizer, new timing chain cover, new water pump, thermostat, new thermostat housing, new high pressure power steering hose, Michelin-X radials, new sunroof assembly, new single-piece lug nuts, new exhaust manifold studs & gasket on driver's side, new Durango alternator. Jeepforum.com sticker, Visit cobaltboatsforum.com when you can!
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Unread 05-01-2013, 06:51 AM   #2
99WJ01TJ
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Although the connection itself could be faulty (examine the connector, the pins inside it and the wiring closely for nicks,pinches,looseness,etc) Try wiggling the alt connector the next time the light comes on. Striking a failing alternator or starter sometimes nudges worn parts just enough for them to work for a while. With a alternator; the brushes are likely worn done and the blow jiggles them enough to connect. That's the problem with moving parts.....they wear out.
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Unread 05-01-2013, 08:33 AM   #3
berndog67
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if u do replace it, make sure to get one for a 2004 durango 4.7L, and check the box and alt to be sure u got a 160 amp one, its a nice little upgrade from the 136 amp one we have in our wj's, and they are usually at least $20 cheaper than the wj ones!
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Unread 05-01-2013, 09:54 AM   #4
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My experience with the denso units used on older turbo/fwd dodges is that the armature often wears excessively, making rebuilding it (replacing brushes) a poor return on time and money invested. Not sure if these are similar, but for the money I'd buy a new one for a durango if you plan to keep the jeep a while.
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Unread 05-01-2013, 07:24 PM   #5
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Quote:
Originally Posted by berndog67 View Post
if u do replace it, make sure to get one for a 2004 durango 4.7L, and check the box and alt to be sure u got a 160 amp one, its a nice little upgrade from the 136 amp one we have in our wj's, and they are usually at least $20 cheaper than the wj ones!
2005+ durango
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Unread 05-02-2013, 05:51 AM   #6
adolphhipster
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2001 durango also
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Unread 05-02-2013, 06:12 AM   #7
Double E
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Super...

The Durango unit bolts up, no modifications?
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2000 Laredo 4.7L Selec-Trac. 177K miles, Leather, 245 tires, tow package, crappy CD changer, full size spare, roof cross-rails & sunroof.
Changes & fixes: Rear Addco sway bar & greasble bushings, upgraded headlights, upgraded tail lights, new hood struts (replaced 2X), new rear hatchglass struts, new radiator (replaced 3X), new oil pressure sending unit (replaced 4X), 2 new speed sensors, 2 new door lock actuators, new ignition key cylinder, chrome front tow hooks, Mobil 1 Synthetic 5/30, Purolator Pure One oil filter, EBC slotted & dimpled rotors, EBC Greenstuff pads, new front shocks (replaced 3X), new rear shocks (replaced 2X), new IRO steering stabilizer, new timing chain cover, new water pump, thermostat, new thermostat housing, new high pressure power steering hose, Michelin-X radials, new sunroof assembly, new single-piece lug nuts, new exhaust manifold studs & gasket on driver's side, new Durango alternator. Jeepforum.com sticker, Visit cobaltboatsforum.com when you can!
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Unread 05-02-2013, 06:18 AM   #8
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The 05 does but there is a tab you may or may not have to cut off. I had to cut off because i drilled out the upper bolt because it was basically welded in the bracket.
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Unread 05-03-2013, 05:59 AM   #9
Double E
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Done. The 2001 Durango unit bolted up perfectly.
The only modification was to the top connector (red wire) from the battery when I had to enlarge the hole of the wire connector to fit the larger post of the Durango alternator.

Cost $75 less than the Jeep spec unit and the Durango spec unit puts out 160 AMP compared to 134 with the OEM.

Anyone care to explain why this is so?
Also, is there any "down side" to a higher output alternator?
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2000 Laredo 4.7L Selec-Trac. 177K miles, Leather, 245 tires, tow package, crappy CD changer, full size spare, roof cross-rails & sunroof.
Changes & fixes: Rear Addco sway bar & greasble bushings, upgraded headlights, upgraded tail lights, new hood struts (replaced 2X), new rear hatchglass struts, new radiator (replaced 3X), new oil pressure sending unit (replaced 4X), 2 new speed sensors, 2 new door lock actuators, new ignition key cylinder, chrome front tow hooks, Mobil 1 Synthetic 5/30, Purolator Pure One oil filter, EBC slotted & dimpled rotors, EBC Greenstuff pads, new front shocks (replaced 3X), new rear shocks (replaced 2X), new IRO steering stabilizer, new timing chain cover, new water pump, thermostat, new thermostat housing, new high pressure power steering hose, Michelin-X radials, new sunroof assembly, new single-piece lug nuts, new exhaust manifold studs & gasket on driver's side, new Durango alternator. Jeepforum.com sticker, Visit cobaltboatsforum.com when you can!
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Unread 05-03-2013, 06:11 AM   #10
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Will the Durango unit fit and work on an 04 GCL 4.0?
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Unread 05-03-2013, 11:00 AM   #11
Double E
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Well...the Durango never came with a 4.0

The Durango Alt unit I used was for a 4.7 and I asked the parts person to bring me a 2000 WJ Alt & the Durango Alt to look at side-by-side and we could see there was a match except for output rating.

Since the WJ 4.7 Alt is not a direct swap for the 4.0 Alt, I'd say no.
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2000 Laredo 4.7L Selec-Trac. 177K miles, Leather, 245 tires, tow package, crappy CD changer, full size spare, roof cross-rails & sunroof.
Changes & fixes: Rear Addco sway bar & greasble bushings, upgraded headlights, upgraded tail lights, new hood struts (replaced 2X), new rear hatchglass struts, new radiator (replaced 3X), new oil pressure sending unit (replaced 4X), 2 new speed sensors, 2 new door lock actuators, new ignition key cylinder, chrome front tow hooks, Mobil 1 Synthetic 5/30, Purolator Pure One oil filter, EBC slotted & dimpled rotors, EBC Greenstuff pads, new front shocks (replaced 3X), new rear shocks (replaced 2X), new IRO steering stabilizer, new timing chain cover, new water pump, thermostat, new thermostat housing, new high pressure power steering hose, Michelin-X radials, new sunroof assembly, new single-piece lug nuts, new exhaust manifold studs & gasket on driver's side, new Durango alternator. Jeepforum.com sticker, Visit cobaltboatsforum.com when you can!
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Unread 05-03-2013, 11:34 AM   #12
99WJ01TJ
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Quote:
Originally Posted by Double E View Post
Well...the Durango never came with a 4.0

The Durango Alt unit I used was for a 4.7 and I asked the parts person to bring me a 2000 WJ Alt & the Durango Alt to look at side-by-side and we could see there was a match except for output rating.

Since the WJ 4.7 Alt is not a direct swap for the 4.0 Alt, I'd say no.
I say find one at a scrap yard and double check. I have a 01 tj I6 & I swapped a 160 amp alternator from a 02 4.7 Durango. Granted the alternator on the I6 wj are in a different location than on a tj......they are the same engine.
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Unread 05-03-2013, 11:35 AM   #13
adolphhipster
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Durango alt works on a wj 4.0 direct fit.
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Unread 05-03-2013, 11:43 AM   #14
Double E
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So if the Durango fits the WJ perfectly as I recently confirmed (2000WJ 4.7 & 2001 Durango 4.7)

...then the WJ 4.7 Alt is also a direct swap for the 4.0 WJ? (all years?)

Not arguing the point either way but want to prevent misunderstandings.
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2000 Laredo 4.7L Selec-Trac. 177K miles, Leather, 245 tires, tow package, crappy CD changer, full size spare, roof cross-rails & sunroof.
Changes & fixes: Rear Addco sway bar & greasble bushings, upgraded headlights, upgraded tail lights, new hood struts (replaced 2X), new rear hatchglass struts, new radiator (replaced 3X), new oil pressure sending unit (replaced 4X), 2 new speed sensors, 2 new door lock actuators, new ignition key cylinder, chrome front tow hooks, Mobil 1 Synthetic 5/30, Purolator Pure One oil filter, EBC slotted & dimpled rotors, EBC Greenstuff pads, new front shocks (replaced 3X), new rear shocks (replaced 2X), new IRO steering stabilizer, new timing chain cover, new water pump, thermostat, new thermostat housing, new high pressure power steering hose, Michelin-X radials, new sunroof assembly, new single-piece lug nuts, new exhaust manifold studs & gasket on driver's side, new Durango alternator. Jeepforum.com sticker, Visit cobaltboatsforum.com when you can!
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Unread 05-03-2013, 11:48 AM   #15
99WJ01TJ
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Quote:
Originally Posted by Double E View Post
So if the Durango fits the WJ perfectly as I recently confirmed (2000WJ 4.7 & 2001 Durango 4.7)

...then the WJ 4.7 Alt is also a direct swap for the 4.0 WJ? (all years?)

Not arguing the point either way but want to prevent misunderstandings.
Correct, but with the Durango unit bring cheaper than a wj unit...it's a no brainer for those of us with tj's . I need to buy one for my 4.7 now too. My alternator is fine but I have lots of offroad lights that draw amperage
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