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Old 01-22-2011, 08:10 PM   #31
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Sweet idea, what's the peak rpms for an alternator? Is it the peak torque of the engine (2700rpms)

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Old 01-22-2011, 08:10 PM   #32
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I am using the same wires as the old one.
i found this about changing the stock wire, scroll down and you'll see a chart that lists the differnt amps to the guage of wire needed

Technical Information

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Old 02-03-2011, 01:53 PM   #33
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alternator upgrade

I have a 06 tj sport that im upgrading to a yellow top deep cycle oreillys battery and im thinkn of upgrading the alternator like you did for my new smittybuilt winch im putting on my jeep. So besides upgrading the amp wire what else info can you give me so i can make the change. Like alternator numer to buy and size wires and do i need to change any plugs for switches of wires or alt change.
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Old 02-03-2011, 02:44 PM   #34
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The alternator that i got pluged right into the factory wiring, I believe that the same alternator that i got would work for yours as well, but you might want to do some searching around first. Mine was from an 06 durango so that would probably work for yours. I posted a pic of the number on the other page, check out that website I posted as well, good prices. Other than that all you need is the 4 gauge alternator wire, about 25'' worth. Just remember that you wont get the full 160 amp off idle, you'll have to rev up the engine to get the full amps.
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Old 02-09-2011, 08:36 PM   #35
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TheTJRod, any updates on your alt swap?
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Old 02-10-2011, 08:52 AM   #36
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Originally Posted by Mike_3303 View Post
i found this about changing the stock wire, scroll down and you'll see a chart that lists the different amps to the guage of wire needed

Technical Information
I still highly doubt that changing the guage of wire will do anything with the voltage being to high. Though I will change it and see if that makes a difference because it is good to do whether or not I am upgrading the alternator. I have been really wanting to change my battery terminal clamps for some time now as they don't seem to clamp down hard enough.(don't read into this as being my problem as a weak connection would only lower my voltage and amp capacity not make it spike)

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The alternator that i got plugged right into the factory wiring, I believe that the same alternator that i got would work for yours as well, but you might want to do some searching around first. Mine was from an 06 durango so that would probably work for yours. I posted a pic of the number on the other page, check out that website I posted as well, good prices. Other than that all you need is the 4 gauge alternator wire, about 25'' worth. Just remember that you wont get the full 160 amp off idle, you'll have to rev up the engine to get the full amps.
My only concern with the new amp right now is that it's putting out 19 volts. This is a sign that the voltage regulator is failing to do it's job though since it works with my stock one I believe it doesn't know how to control the new one. It is also possible that the alt I have is damaged in a way that misinterprets the signals. Our Jeeps have external regulators located in the PCM. I have verified that it works properly as it can control my stock alt perfectly fine. I have also checked if I plugged in the wires the correct way on the new alt as it only starts to put out voltage when it is on the right way. I have also verified that I have the same part number as a 06 Durango alt. If you go to that website Pams Auto and look for that alt it recomends the alt from the Liberty as a replacement.

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TheTJRod, any updates on your alt swap?
Sorry I have been busy with work and the superbowl coming up took my time.

I have taken all my voltage readings with the positive end directly on the positive bolt of the alt and the ground on the chassis or negative battery terminal. Oh, while I was doing all of this I grabbed a wire brush and scrubbed all the connections.

I am going to try and get a bunch of 4 guage wire and replace the "big 3" and see if that has any impact. I will also try to take my alt into the auto store to have it tested. It looks practically new but was taken from a wrecked vehicle so something could have been shaken loose or broken something from the vibration.

"big 3"= the three main power wires. +Alt to battery, -Battery to engine block, -Block to chassis. Other wires that could be upgraded for better overall electrical efficiency is the +battery to fuse block, +battery to starter
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Old 02-10-2011, 09:21 AM   #37
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Mike, did you get your alt from a 4.7L or a 3.7L? I am trying to find if there is any small difference in the two alts that make them incompatible on some dodge truck forums
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Old 02-10-2011, 10:00 AM   #38
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If the new alternator is putting out 19v then the voltage regulator setup must be different for the 2. My guess is you will not be able to control the new one to bring it back down around 15v. Unless you have excessive resistance on the ground side and it thinks the voltage is really low.. I guess that might help. I just did both ground and hot cables in my engine bay with marine grade 2 gauge wire and it actually runs better. IN FOR RESULTS, because this is my next mod.
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Old 02-10-2011, 10:08 AM   #39
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I haven't found anything showing that the 3.7l and 4.7l are incompatable with each other. They also use grand cherokee alts for upgrades. Oh and was also trying to find what would cause high voltage in an alt. And the more I read the more I think some people should never touch anything that is under their hood. Like people driving their car with the gauges flickering and having to refill their battery every few days like it's not a serious problem. Other people not knowing the difference between amps and voltage. The guy installed an ammeter in he car and was freaked out when it jumped from 30amps to 60amps when he pressed on the gas. Though when the gauge started smoking he decided to start carrying a cup of water with him "just in case" it caught fire! This guy should have immediately stopped his car and had it towed. What is even sadder is that his forum isn't really telling how bad it is, or telling him that he doesn't know what he is doing and could destroy his entire electrical system that will cause problems for the life of the car. Or tell him this is how car fires are made. He stopped posting abruptly so I can only assume his car caught fire with him in it.

On a side note, I believe either the alt is incompatible(though is the same part number of OP) or I have some broken or shorted diodes in the alt.

Mike, could you do me a favor and take a pic of the plug on the alt with the cable disconnected. I want to take a look and where the pins are oriented and the groves in the plastic on the plug

This is my plug to the alt
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Old 02-10-2011, 10:42 AM   #40
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From what I've read elsewhere, there are certain years where the voltage regulation is done through the alternator rectifier and earlier years it is through the PCM. I feel this is your issue.
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Old 02-10-2011, 03:10 PM   #41
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Originally Posted by TheTJRod View Post
I haven't found anything showing that the 3.7l and 4.7l are incompatable with each other. They also use grand cherokee alts for upgrades. Oh and was also trying to find what would cause high voltage in an alt. And the more I read the more I think some people should never touch anything that is under their hood. Like people driving their car with the gauges flickering and having to refill their battery every few days like it's not a serious problem. Other people not knowing the difference between amps and voltage. The guy installed an ammeter in he car and was freaked out when it jumped from 30amps to 60amps when he pressed on the gas. Though when the gauge started smoking he decided to start carrying a cup of water with him "just in case" it caught fire! This guy should have immediately stopped his car and had it towed. What is even sadder is that his forum isn't really telling how bad it is, or telling him that he doesn't know what he is doing and could destroy his entire electrical system that will cause problems for the life of the car. Or tell him this is how car fires are made. He stopped posting abruptly so I can only assume his car caught fire with him in it.

On a side note, I believe either the alt is incompatible(though is the same part number of OP) or I have some broken or shorted diodes in the alt.

Mike, could you do me a favor and take a pic of the plug on the alt with the cable disconnected. I want to take a look and where the pins are oriented and the groves in the plastic on the plug

This is my plug to the alt

Yeah i can get you a pic, I'm at work right now so i wont be able to post one till tomorrow when i get time to take a pic. I understand that changing the wire wouldnt help your voltage problem i was just suggesting that its a good idea to do it when you install this alternator. And mine was from an 06 durango with the 4.7
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Old 02-16-2011, 11:40 AM   #42
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I took the alt into Auto Zone and had them test it referencing the Wrangler. It wouldn't even go through the first test. I am heavily doubting the competence of the workers there as it took so very long and a half dozen tries or more. I think he just gave up, he said it was bad blaming it on bad bearings and probably bad diodes. I also took it into Advance Auto Parts referencing the Liberty. The alt tested out just fine putting out 14.7volts with no load which was within manf. specs. My thoughts are that it will not work in my Wrangler.
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Old 02-16-2011, 02:50 PM   #43
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I took the alt into Auto Zone and had them test it referencing the Wrangler. It wouldn't even go through the first test. I am heavily doubting the competence of the workers there as it took so very long and a half dozen tries or more. I think he just gave up, he said it was bad blaming it on bad bearings and probably bad diodes. I also took it into Advance Auto Parts referencing the Liberty. The alt tested out just fine putting out 14.7volts with no load which was within manf. specs. My thoughts are that it will not work in my Wrangler.

Hey, i'm sorry I didnt get the pictures up like i said i would. I've been busy, just got engaged on monday! Anyway, your plug looks the same as mine, and the 160amp alt i have has the same port as the stock one. Thats such a bummer that its not working, you could always try another alternator if you want. But does it do the same thing if you put the stock alternator on? If so it could be something different like the computer, but it seems like it should work. Here is a pic anyway.
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Old 02-16-2011, 04:15 PM   #44
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I was kinda meaning for you to take one of the plug on your alt. But if you say your plug went in with no problem then the alt I have doesn't have the right plug. I had to file down the pins on the plug on the alt to get it to fit. I guess it is going on ebay and I am buying a new one.
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Old 02-16-2011, 04:40 PM   #45
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I was kinda meaning for you to take one of the plug on your alt. But if you say your plug went in with no problem then the alt I have doesn't have the right plug. I had to file down the pins on the plug on the alt to get it to fit. I guess it is going on ebay and I am buying a new one.

Ahh, well it looks the same as the stock alternators plug. Are you going for a replacement alt, or trying another 160amp?
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Old 02-16-2011, 05:32 PM   #46
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Can anyone verify for me what year Durango 160amp alts with fit my 2002?
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Old 02-16-2011, 06:00 PM   #47
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I belive that 2002-2006 and i even think up to 09 will work. I have an 03 and i got mine from an 06 durango with the 4.7L.
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Old 02-16-2011, 06:14 PM   #48
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I did a little parts referencing (car-parts and advancedautoparts) and 01-06 seem to share the same alt. I've read all this BS where 04-06 have internal v-regs but I don't believe it. I just ordered an 04 alt off of a Durango 4.7L that had about 90k and looked pristine except for the massive damage from a side impact Pams auto is a sweet website! I wish they had some 90-95 Ford Taurus fans, nowhere around here has them or if they do they want $80 for a junker fan! I'd rather buy new from online! Going to be back in MA and I'll be hitting my favorite junker, $15 for a single fan, $25 for a double
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Old 02-17-2011, 08:40 AM   #49
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Ahh, well it looks the same as the stock alternators plug. Are you going for a replacement alt, or trying another 160amp?
Well the alt tested good and it fit perfectly in the stock location but the plug wasn't the same and wasn't being controlled properly.

I still have my original alt that I will be using. I am going to try and see if pam's auto will do an exchange for me. As I was looking up durango alts and their cross reference system suggested the '10 Liberty alt.
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Old 02-21-2011, 07:42 PM   #50
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That could be right. If you go to their website, go to the perfect match part section on the homepage. Look up the same year as your jeep but go under dodge truck then click on durango, then the 4.7l engine. Thats what i did for mine. I also just tested out the 160amp aternator today while running my winch under load. It out performed my stock hands down. The the stock alt my volt gauge pegged the bottom and the engine light came on. With this replacemet the gauge didnt even move halfway to red. I really hope you can find one that will work.
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Old 02-28-2011, 02:19 PM   #51
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My alt came in last week. Haven't had time to install it. I still need to get a larger cable to go back to the battery. The alt is rusty as hell, including the pulley, any ideas on how to clean it up or should I just swap pulleys if possible? I'll post pics tonight
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Old 03-03-2011, 09:31 AM   #52
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My alt came in last week. Haven't had time to install it. I still need to get a larger cable to go back to the battery. The alt is rusty as hell, including the pulley, any ideas on how to clean it up or should I just swap pulleys if possible? I'll post pics tonight

Some steel wool would clean up the housing just fine, as for the pully it depends. If its just a little surface rust it should be ok, but if its affecting the spin of the pully, such as if its grinding or catching, then you might want to change it. You can get the battery cable at any auto store, just remember that it goes to the fuse box and not the battery. Unless yours is set up different than mine. Just follow the cable and see where it take you.
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Old 03-03-2011, 06:21 PM   #53
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Do any fuses need to be changed out? I've seen some vehicles with "master fuses" rated for the alternator

As for the alt, the housing is pretty rust free but it's the pulley I'm concerned about. The alternator motor spins very freely and cleanly but check out my pulley




I managed to clean it up pretty decently with a dremel, such a nice tool to have around for small projects, here is the end result



I might go get a couple more wire wheels and go at it again, the above was done with 2 and I destroyed them haha

More pictures here: ImageShack Album - 6 images

Thoughts and input? I'm going to need to go out and get the right wrench to get this sucker off if it comes to it
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Old 03-03-2011, 06:48 PM   #54
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I managed to clean it up pretty decently with a dremel, such a nice tool to have around for small projects, here is the end result

I might go get a couple more wire wheels and go at it again, the above was done with 2 and I destroyed them haha

Thoughts and input? I'm going to need to go out and get the right wrench to get this sucker off if it comes to it
I would suggest wire wheels for your drill or even angle grinder. I have been able to clean lots of rusty things super quick with the angle grinder.
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Old 03-03-2011, 09:03 PM   #55
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It looks a lot better than before, good job! I'm not sure on the fuse for the alt tho. I havent replaced mine and havent had any problems so far, no melted wires lol. But I would do some research on it, I could have missed that and it might be something that needs to be done, but like i said, no problems so far and i've had it on for a few months now. I've done a few long driving trips and even used the winch without any trouble.
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Old 03-03-2011, 09:04 PM   #56
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I would suggest wire wheels for your drill or even angle grinder. I have been able to clean lots of rusty things super quick with the angle grinder.

Have you decided what you're going to do with your situation. Getting another 160 or just sticking with the stock alternator?
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Old 03-04-2011, 06:08 AM   #57
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I would suggest wire wheels for your drill or even angle grinder. I have been able to clean lots of rusty things super quick with the angle grinder.
Ya I know, I need some more tools :-( gotta start with the drill first LOL going to get a semi cheap 18v cordless and maybe some harbor freight grinders for cheap?
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Old 06-20-2012, 04:55 PM   #58
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I just did this mod with a durango 160 alternator ito my 03 tj and it works great---Couldnt be happier with the performance and savings!$$$$
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Old 06-20-2012, 09:00 PM   #59
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other than helping with a winch, what other benefits are there ?
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Old 06-20-2012, 10:21 PM   #60
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Quote:
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other than helping with a winch, what other benefits are there ?
Less stress on your battery and alternator when jump starting someone.

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