1974 CJ5 Which Internal Regulated Alternator to upgrade to and how - Page 4 - JeepForum.com
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post #46 of 47 Old 10-12-2015, 06:54 PM
Web Wheeler
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1978 CJ5 
Join Date: Jan 2009
Location: Beach City
Posts: 6,807
I would try to stick to a fusible link wire or I bought a weather proof circuit breaker. I popped my original fusible link when I was winching once - had the rpm set to 1500, 70+A alternator, and about 10' into the pull I lost the charging system.

I don't recommend a fuse, as after a while the connections may become loose/dirty and then the holder heats and fails. Or you get an amp spike and it pops to easily. I'm going to be replacing my headlight fuse soon with a breaker as the terminals have come loose a couple times and I've melted 2 fuses. Corrosion from winter water splashed and loose connections caused some heat. Someday I'll have the time to do the relay upgrade.


1978 CJ5 5.0HO/T177/D300, '86 D30/D44 WT axles, 'glass body, 31x10.5 BFG A/T, TDK galv'd frame - DD and weekend toy

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post #47 of 47 Old 10-13-2015, 05:27 AM
Mike Romain
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1986 CJ7 
Join Date: Nov 2007
Location: Off the Grid in Chester Grant
Posts: 18,083
Fuse link wire is the best way to go. It sells by the foot and needs to be crimped in place, solder damages its properties.
Normally you use a link wire 2 automotive gauge sizes smaller than the wire being protected. So for a stock 10 ga. alternator wire, you use 14 ga. fuse link wire.

86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
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