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Unread 07-05-2010, 10:09 AM   #1
timberwolf0122
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Durango Alternator Swap with pictures!

So I finally got round to swapping out my boring old stock alternator (LJ 2005) for a sexy new(used) 160Amp Alternator from a 2002 Durango.


The stock alternator is on the left and the durangolt's is on the left, despite the size difference it is a direct bolt in replacement.


Safety 1st, safety 2nd, I disconnected the +ve lead from the battery and secured it out the way with the battery tie down, now my only danger was the scorching sun.
I had replaced the stock battery 2 days ago for a Bond platinum 34/78 (1090 CCA! for under $100), which is why it is the only clean thing under the hood.


With the power disconnected I removed the alternators 2 wire plug and the power cable that leads from the alternator to the +ve battery terminal


Time to take the fan belt off, I'm glad I put a flexilite fan in, now I have room to work!


The tensioner has a 1/2" socket so it is a peice of cake to release the tension with a socket wrench and slip the belt off the idler.


Undoing the two bolts (15mm) that held the stock alternator was the hardest part of the job (they were on good), it took 20 minutes of cursing and soaking in PB blaster be they relented.

A further 10 minutes of cursing ensued as I tried to get the new alternator to fit on to the mounting bracket, it would almost go but I could not get the bolt through....


Then I noticed this, the bottom mount has a sort of nut-sert thing on it that held the bolts thread and it was stick out on the inside too far!, 30 seconds later I had tapped it out all of 1/16" and bingo! everything lined up!

I tightened everything down good an solid reattached the cables to the new alternator and the battery, re-fed the fan belt, then with crossed fingers jumped into the cab and started her up.
It's always a good feeling when not only does the engine start but it runs and there are no loud bangs or screeches. :-)

I've done a couple of tests with the 1500W inverter running an 800W drill and I can run it alot longer and harder before the voltage drop alarm goes off!

Comming soon(ish) Dual battery install write up and a winch install!

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Unread 07-05-2010, 10:54 AM   #2
02OlllllllOTJ
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ive heard of this swap, what are the advantages of it? i know it has a higher power output but is it needed? i have a winch running of a optima yellowtop and runs great. is this swap mostly for people running a lot of electronic extras?
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Unread 07-05-2010, 11:10 AM   #3
chmo
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wow ... I wish I could get one too

last night drive with all my four KC highlites (130W x 4) I had a low voltage alarm after having my car idling for 15-20 minutes or so with the complete lightning on ...

after switching the auxiliary lightning off and driving for a while the voltage was back again

my stock alternator is not providing enough at 700 rpm

so the question now is : does the durango alternator provide much more at low rpms as well ?
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Unread 07-05-2010, 12:50 PM   #4
tulman22
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Very nice and clean. Been thinking of doing this before adding more lights. Actually easier than I expected. Now just to find the Durango alternator for the project.
What did the alternator set you back?
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Unread 07-05-2010, 02:10 PM   #5
Vic99TJ
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Very cool do you know how much a new duranga alt. costs?
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Unread 07-05-2010, 02:54 PM   #6
TJBoomer
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Checked Orielly's Auto Parts on the web. 2002 Durango 160 amp alternator remanufactured is $150. Not sure if there is a core charge or not. Probably is though.
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Unread 07-05-2010, 03:46 PM   #7
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I'd like to know the voltage output at idle as well. There could potentially be some adjustment with swapping pulley sizes, but I'm not sure how much. If anyone has the idle output numbers, please post them.
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Unread 07-05-2010, 05:32 PM   #8
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I bought my alternator from ebay used (30,000 miles), I paid $30+$12 shipping. According to the dash I am sitting pretty much on the 14V marker, I'll have to stick the multimeter in the lighter port and get a precise reading.

A 160A alternator will put out more power at any RPM range than a 90A (stock) alternator.
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Unread 07-06-2010, 05:11 PM   #9
bob_351c
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did you upgrade the wiring? going from 90 amp to 160 is a huge jump and i doubt the stock wiring can safely handle that
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Unread 07-06-2010, 06:56 PM   #10
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Here ya go. 165 amp direct bolt in. No modifications required. These, from what I understand, are stock alternators that are rewound and rebuilt to a higher output so they bolt right in. Excellent warranty as well. "WE GIVE YOU A LIFETIME WARRANTY!" Great people. $150. Got one 8 years ago and no problems so far. It's great.

91-98 NEW JEEP CHEROKEE YJ/TJ HIGH OUTPUT ALTERNATOR 165A

1-800-607-0016 (Dallas, TX) and I'd guess they might answer the above questions about the required wiring and output at idle.
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Unread 07-06-2010, 07:54 PM   #11
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Quote:
Originally Posted by bob_351c View Post
did you upgrade the wiring? going from 90 amp to 160 is a huge jump and i doubt the stock wiring can safely handle that
Yes you should upgrade the wire that goes from the alternator to the battery.
Edit: Keep the 10 AWG fusible link...
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Unread 07-06-2010, 08:28 PM   #12
bob_351c
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does the factory wiring have a fuse link between the alternator and battery? i would think so, and this could burn up leaving you stranded
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Unread 07-06-2010, 09:03 PM   #13
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Originally Posted by bob_351c View Post
does the factory wiring have a fuse link between the alternator and battery? i would think so, and this could burn up leaving you stranded
Edit: Yes, it does...
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Unread 07-06-2010, 09:30 PM   #14
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From 04-06 Jeep changed to a different alternator which was typically rated at 117 Amps, voltage output at idle should not change because this is controlled by the internal regulator, the real difference is how much amperage load it will handle at a given rpm to maintain acceptable voltage before alarms go off. If you run a winch you will exceed the amperage capacity of an alternator and draw the additional amps from the battery during a pull, once the amperage drain depletes the battery reserves voltage will begin to drop setting off the low voltage alarm. With more amperage capacity from the alternator your pulling less amps from the battery during a pull so the battery will drain less over the duration of a pull. Amperage draw specs for your winch can be found in the mfg specs and varies depending on load and how many layers (wraps) are on the drum. Here are the specs on a Warn 9.5ti Winch to give an idea how much amperage (current) the winch motor will draw off the electrical system. Any line pull over 2000lbs will max out a 160 amp alternator and begin draining the battery. This means anyone with a winch will benefit by upgrading the alternator.

Timberwolf0122, I've been looking through salvage yards for my 06 alternator upgrade but there are many different part #'s used on the Dodge trucks, could you please post the part number on your 05 upgrade? I'm not sure if my current part # is correct but I can cross reference them?

(136A Alternator from 97-98 ZJ, Dakota, Durango, Ram (PN:56027913) fits 97-03 Wrangler)
(04–06 Durango with 4.7/160A (PN:56029914AA), fits 04-06 Wrangler)

WARN 9.5ti Line Pull Lbs. to motor current load rating.
0 lbs = 47 amps
2000 lbs at layer 1 = 160 amps
4000 lbs at layer 2 = 230 amps
6000 lbs at layer 3 = 305 amps
8000 lbs at layer 4 = 370 amps
9500 lbs at layer 5 = 425 amps

Last edited by Guardian7; 07-08-2010 at 12:59 AM..
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Unread 07-06-2010, 09:56 PM   #15
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Quote:
Originally Posted by TJBoomer View Post
Here ya go. 165 amp direct bolt in. No modifications required. These, from what I understand, are stock alternators that are rewound and rebuilt to a higher output so they bolt right in. Excellent warranty as well. "WE GIVE YOU A LIFETIME WARRANTY!" Great people. $150. Got one 8 years ago and no problems so far. It's great.

91-98 NEW JEEP CHEROKEE YJ/TJ HIGH OUTPUT ALTERNATOR 165A

1-800-607-0016 (Dallas, TX) and I'd guess they might answer the above questions about the required wiring and output at idle.
Looking through their site, am I correct in assuming that for my 99 SE 2.5L, I would have to go with the $200 175A model?
99-00 NEW JEEP CJ WRANGLER YJ HI OUTPUT ALTERNATOR 175A

The picture on the $200 model is identical to the lower rated 165A, so I would assume they are compatible, but I may call them to ask.
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