selarep said:
Could you give us some more info on that? Some of the threads I have been reading only talk of replacement of the alternator and nothing of the wiring, I was looking at getting a ZJ V8 136 amp alt. but I was concerned with the wiring.
Thanks 5-90
Chrysler (and Ford, come to think on it...) are both notoriously cheap on wiring. They use
just enough wire cross-section to handle anticipated current loads, and no more (that's why the AMC harnesses will handle up to 80W on headlamps, while ChryCo tops out at 65W, for instance.)
While you're alternator doesn't "live" at full output (typically, it's down around 50-60A for most modern vehicles,) the first time you need all of it, you're going to either blow out your fusible link or just melt down the output lead. And just
try finding fusible link wire anywhere in 10AWG (Hell, I've been looking off and on myself.)
Early PDCs use a pair of MAXI 60 fuses in the PDC for alternator output circuit fusing - since MAXI fuses can be had up to 80A, you can honestly get up to 160A of protection for that circuit. However, I usually suggest replacing with an ANL fuse - which can be had up to around 600A (so 200A for Mean Green units isn't a problem at all - I carry them from 100-200A in various "steps.") Upsize your output lead, install an ANL fuse block, and you're good. Upsize your alternator later? Install a larger fuse (keep the smaller one - you can "limp home" on it if you identify the problem and turn a few things off.)
Typically, the OEM output lead is 8AWG or thereabouts. Fine for an OEM alternator - but once you go up past OEM levels, you're going to want something bigger. 4AWG will carry you safely up to 150-160A - beyond that, just do 1AWG and call it good (since 1AWG, in the lengths usually used, is good for somewhere around 350-375A without overheating.)
Make sense now?