I just ordered the aforementioned 120a version from there based on your recommendation. Should arrive by week's end. The current 90a/OEM style alt is only like 4 years old and is still putting out 14a or so while idling, but it never hurts to upgrade and save the other one for a spare. I did the big 7 upgrade already, but I had to dremel off some of the plastic on the retainer-thingy to make the 4ga cable fit. Kudos to you for getting it in. I do *not* have that kind of patience apparently.

 

Getting in to a 4x4 conversion on my 93 cherokee. Bought a d30 from the the junkyard and its in pretty good condition but the passenger side wheel hub has some play. Maybe the wheel bearings are shot? Or maybe i should just try re-seating everything?

Anyways i need to fix that play before i drive it because the last thing i need is for my rig to wobble out on the freeway and rip apart my front end. Im looking in to maybe replacing just the bearings themselves. Then i could possibly swap in the ones from my old axle. If thats not an option ill need to purchase the whole hub assembly because the hubs from my old 4x2 front axle dont appear to have an insert slot for an axle shaft..... Hhmmmm......

 

I'm digging the paint on the knuckle!

 

I've been fiddling with my wifes '01 since last Wednesday when a low voltage issue arose. I got it home and did some research here on the forum.

I decided to start by cleaning up all the grounds, didn't go too well at first. I broke my 10mm on the first bolt I tried to loosen and then dropped a different socket down onto the bell housing... The socket on the bell housing was a serious pain to retrieve but I got it, even though it took several hours over a couple days. I also broke the eyelet off the chassis to battery negative ground, but got that replaced too.

Cleaning the grounds didn't help my low voltage so I pulled the alternator and had it tested at AutoZone. It failed so I got a 117A reman. Finished going over the grounds and got the new alt in today and now it's back on the road after a week of difficulties.

I also had some spare time after I finished the alternator to inspect and repair the headlamp switch on my '99.

It was a good way to end a tough week for me and my XJ's.

 

Also converting a 2001 to 4WD, oversaw my 19yo son tear into the TC for a JB SYE install. I have two 98s for donors but found this TC hooked to an AW4 for a bennie about 8 miles away. Trust thy neighbor.

4WD parts not pictured, HP D30, Novak shifter, also doing drivers door pins. Spartan rear and headliner done.

 

Right on!
To be fair: I had it all inside to test fit it since it was so damned cold out.

 

I mean either way right? About 96% of my repairs get done on the rig, this will be no different. So maybe if it wasn't such an awkward angle--either you're reaching down from the top or over your head on a creeper, and these alternators aren't light.

Speaking of, good steer on the link, AF. I was shocked to discover the unit l purchased from MC on Sunday night had arrived this PM. It's *so* shiny I'm not sure I want to put it on yet :P

Seriously though, the included build sheet says it tested up to 150 amps at 3K RPM. AND it really does look plug and play, which is a relief because I sure suck with a grinder. If it weren't dark and cold for Florida (it's like 45 degrees, brrrr) I'd be out there putting it in.

 

Awesome! You mazzo!! 45° is heat wave up here.
You have to love the warranty, support, shipping speed and coreless sales setup.
I hope it goes in as easily/quickly as it arrived.
TIMMY!!
My recent entry for the Squeeze The Scale Challenge. hehe!!

 

So I took the day off from work so I could attempt this alternator. I have to say, it's not going too well. I had to grind after all.

The skies opened up just now so had to take a break but I'll get her in. Currently cursing and grinding and cursing and grinding the bracket so this behemoth will fit.

 

I can't wait till I try to squeeze the 160amp alternator into mine.

Its a stock 160amp delco from a durango, if you were curious.

 

In anticipation of getting a bigger alternator I scoffed some extra brackets for it.
My thinking was grind those on the bench.
Not sure if I that idea would even work cause I chose a different route.
Had a guy I know up the amps in a stock alternator.
That unfortunately did not work out to well. Had a problem with the output when the Jeep got warmer.
Dropped it back off to him and he fixed it.
Not sure what the problem actually was though.
Will find out if it works properly in the Spring when I throw it back in.

 

Grinding on the bench is a great idea, and probably necessary.

Well, she's in. I had to finesse the install somewhat as my grinder pooped out and I couldn't drive to HF for a new one. In the end I had to skip the bottom bolt for now until I get some new gear this weekend. It runs fine but it is stretching the belt to the limit as I had to give up a few mm due to it not fitting exactly. It will get me to work and back but I wouldn't exactly go cross country in it until I get my grind on for real. For now it's torqued down to withstand a nuclear winter so I'm not scared.

The rocker switch and relay came in for my back door horn install. I just can NOT seem to figure out why it's clicking and nothing else so I'm going to end around this thing. I work in a place where horns are an absolute must or I get run into by retirees who can't stay in their lanes...so it's ghetto solution to the rescue.

 

Took a trip of approximately 600 miles this past week. It was a deer hunting trip and my XJ did really well, facing a stiff headwind from the North going up and hauling a rear tine tiller on a hitch hauler as well led to 17.5 mpg. On the first night, the XJ got snowed on pretty well.


All went well, except I tried to let the wipers clear the snow before it had melted and afterwards the intermittent delay feature and the "park" feature on the wipers doesn't work anymore Now that I am home, I will be pulling the wiper motor to see if it is something I can fix or a new motor is in order.
On the trip home, the old girl ran at a 20.4 mpg clip! No tail wind, but a hard sideways wind made steering a old XJ fun!

Will have to get it cleaned up once I check out the wipers!

 

I figured I could mock everything up, see where I had to grind, grind some, mock it back up,
grind a little more, mock it back up, grind a little more, well you get the idea. LOL.

 

I think I screwed something up. On my way back from work today I had to accelerate and swerve to avoid an accident, and I swear I heard a *pop* somewhere...pulled over, popped the hood and everything looks and smells normal, but it's running on 5 cylinders sounds and feels like. No CEL is on.

I managed to limp it home as it backfired and otherwise complained thoroughly for the remaining 3 miles or so.

Here are my theories:

1) I didn't transfer the old pulley off of the old alternator, and the new one is 1/4" bigger diameter. This combined with the fact that I need to grind more on bracketry which caused me to miss a bolt hole, I lost a good 5 or 6 mm there. This would explain the adjustment tensioner all the way out and me having a hard time getting it on at all. I cannot believe I zoned this. That's just plain dumb.

2) Wonder if when I had to floor it that the apparent lack of tension somehow messed up my ignition timing?

Either way, guess I have my work cut out for myself for the next couple of days.

I am really hoping that it's just a simple timing issue that I can fix and not something more mechanical than this, which would probably mean me shopping for a new block.