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Need help with upgrading electrical system xj

JMOliver

NAXJA Forum User
Location
North Carolina
I have a 1999 xj and want to upgrade alternator and wiring, can someone tell me what alternator I need? ( wanna do around a 160amp ) and I can't find nothing on the wiring either was hoping to purchase a kit from 5-90 but seems he's no longer around from the searches I have done!

Thanks!!
JMOliver


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Dodge Durango for the alternator I believe there's a few post on here one what years you need. As far as the wiringall do you want to replace?
 
I ordered a 02 Durango 160 alternator this morning and 7.5' of black 2 gauge and 7.5' of red 2 gauge. Also ordered heat shrink and 10 2 gauge lugs with 3/8 holes, and a lug press tool. Just now needing to know if I need some fuses?


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I ordered a 02 Durango 160 alternator this morning and 7.5' of black 2 gauge and 7.5' of red 2 gauge. Also ordered heat shrink and 10 2 gauge lugs with 3/8 holes, and a lug press tool. Just now needing to know if I need some fuses?


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Yes it's very vital to have a fuse protecting the system from overload. Because you have a 160 amp alternator, I recommend 175 amp fuse.
 
This is what I can't find where does this fuse go? At battery? Does there need one to pcm? I wish there was a write up for 99+


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This is what I can't find where does this fuse go? At battery? Does there need one to pcm? I wish there was a write up for 99+


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The fuse is the fusible link running from the alt to the pdc. I can't remember what it's rated it but I think it's around 130 or so. I'd just get a big fuse holder and fuse to eliminate the risk of the link quitting. You can always jump a fuse in a pinch ( I haven't had to yet but I can)


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just to help clarify... they cable from the battery to the PDC (power distribution center) IS the fuse. hence the name, fusible link.

i used a 150a fuse and was able to mount it quite neatly to the pdc without a fuse holder. buy 2, dont count on someone having one if yours fries.
 
So the only fuse that's needed on a 99+ is the one at the side of the pdc where the main cable from the battery goes to correct?


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Here's what I've bought so far plus 4 176 amp fuses


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So it's looking like the cost if doing it yourself with inferior crimps is only going to save 20 or so bucks over ordering a complete set from XJWonders. If I can ever get to this, I'll just order a complete set.
 
So it's looking like the cost if doing it yourself with inferior crimps is only going to save 20 or so bucks over ordering a complete set from XJWonders. If I can ever get to this, I'll just order a complete set.

First, you can't assume inferior anything because you don't know of the quality of the end user's work to make a judgment such as that. Secondly, it's always worth much more than you can put a price on to learn how to do things yourself. If/when something happens out in the field, your knowledge is what you have to depend on. Purchased products support pages don't come up in the boonies.

With that said, I opted to make my own battery cables such as the OP did and I wouldn't have it any other way. I saved on the cost of paying for something else to do it and if $20 is the only savings involved in doing it over a seller, then that seller isn't pricing his product right because that's too tight of a margin to make it worth doing business for.

Good job OP!!!!
 
I would of bought a kit but didn't get no feedback on where to buy a kit at first so I opted to buy and build my self and the help of y'all, plus in the end I will have the knowledge and the tools for the next project when it arises, been needing to buy a lug tool for two years now anyways to fix mower battery cable ends when I get them in, so it's a win win. Parts are arriving tomorrow besides some odd stuff I will be awaiting on.if anyone has install pictures I would appreciate if you could post them ( especially the fuse install )

Thanks and anymore info is available I'd love to hear it!


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First, you can't assume inferior anything because you don't know of the quality of the end user's work to make a judgment such as that. Secondly, it's always worth much more than you can put a price on to learn how to do things yourself. If/when something happens out in the field, your knowledge is what you have to depend on. Purchased products support pages don't come up in the boonies.

With that said, I opted to make my own battery cables such as the OP did and I wouldn't have it any other way. I saved on the cost of paying for something else to do it and if $20 is the only savings involved in doing it over a seller, then that seller isn't pricing his product right because that's too tight of a margin to make it worth doing business for.

Good job OP!!!!

It has nothing to do with the op's ability. A hammer crimp is going to be inferior to a crimp done with a 20 ton press.
 
It has nothing to do with the op's ability. A hammer crimp is going to be inferior to a crimp done with a 20 ton press.
I worked on battery-powered industrial equipment for many years.
While I prefered using a big bolt cutter-type crimper, the hammer-type worked fine for field repairs, making hundreds of crimps over the years.

I have both a hammer crimper, bought at West Marine 30 years ago, along with a more recently acquired a HD crimper, bought for use wiring motorhomes and boats.
https://www.delcity.net/store/Heavy!duty-Hammer-Cable-Crimper/p_10383
https://www.amazon.com/FTZ-Correct-...=2025&creative=165953&creativeASIN=B00DZPS1OO

As long as you start with clean cable and lugs, you can make a good connection with hammer crimper, if you pay attention. Make sure to use the right size lugs.
To keep the connections intact, use adhesive-lined shrink tubing.
Much of my Jeep and old motorhome are wired with hammer-crimped connections. None have gone bad in over a decade of use.
That said, the lugs crimped with the FTZ crimper are beautiful compared to any hammer crimp and are what paying customers expect.
If you suspect a crimp isn't good, check for voltage drop over the crimp, when the circuit is under a heavy load. I do this periodically to make sure nothing is going bad.

Once you own a good crimper, it can pay for itself, making up cables for others.
 
I had a custom built Durango alternator that put out 225 amps. I had a huge sub/amp in my Jeep at one point. The amp was capable of drawing over 200 amps. I can't for the life of me remember who built it, was almost 10 years ago and it's still going.
 
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