5.2 l zj alternator in xj help 136a

93 4.0l

I am trying get this thing in and the bottom bolt holes is about a quarter of an inch off.. any suggestions?

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I had to do some clearance grinding inside the bracket if I remember correctly.

You have to grind the bracket in 2 or 3 places. Its a LOT easier to take the bracket off of the jeep and fit the alternator do it outside using an angle grinder.

It's going to hit your timing cover and the brackets. Break out the grinder,it's easy. Did you get a fuse?

4x4JeePmaNthINg said:

It's going to hit your timing cover and the brackets. Break out the grinder,it's easy. Did you get a fuse?

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no I didnt know about a fuse.. can you elaborate?

grinding the bracket and brace just like cal said

grinding the timing cover just like 4x4JeePmaNthINg said

all plugged in

installed

running

I found what you were talking about the fuse.. well I just went ahead and boughta set of upgraded cables and they come with the proper fuse

Very nicely done! I envy the grounds for your tyoe alternator, good that you did the wiring upgrade to. I just upgraded my alt last month. All wiring 1awg lol, overkill. forget if I picked the zj or Durango 136A alt, whichever was cheaper lol.

I don't know when the cables should be here but I can't wait for them.. I got a 2awg kit

I should be on to drive on it for a week until the upgraded cables get here?

I believe you can swap in a 160A Durango Alt with the same process

I have a 5.9 ZJ as well as my XJ. I upgraded my 5.9 to a Durango 160A alternator, since the 150A stock one is no longer available. I am pretty sure the 160A Durango would work with this XJ swap with the wiring conversion that I did to make it work on a ZJ.

160amp 2001-2003 Dodge Durango I got AC Delco part # 334-1446 off of RockAuto. The plug for the back of the Durango alternator I got off of EBay for $12.00. - https://www.ebay.com/…/ALTERNATOR-REPAIR-PLUG-…/291611891043. You simply cut the wires going to your Alt before the black connecting box, there will be 3 wires going into the box, a green, a green with purple stripe and a thick black ground. I soldered the green to green on the new harness/plug and green/purple to the black on the new harness/plug . I then just extended the thick black ground wire and put a new eyelet on it and attached it to the top of the alt bracket (where the brace between the manifold and alt bracket is bolted) . The new post on the Durango alt is too wide for the eyelet on the original red charge wire, simply open it up a little wider with 5/16 drill bit and it will fit.

Stock ZJ Alt and new 160A Durango Alt



Alt that I used for the swap



New plug that goes into the back of the Alt



Opening up the red charge wire to fit



Just another option.

chickenbot said:

I should be on to drive on it for a week until the upgraded cables get here?

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I think you should be ok, though not advisable for long term. Just don't use anything that puts big draw on your system, nothing in the stock pdc is ment to handle that, it's why your new wiring kit has a bigolfuse.

So I got my cables in today and having a little trouble.. my alternator wire that I pulled off went to a plug. I try to follow the wire that it plugs to and the wire disappears under the fuse block. Am I supposed to follow the old alternated wire and plug it in there or do I connect to to the main power connect at the end of the fuse block? Also if I plug it into the end, do I remove all the old wiring from plug to block?

On my 2000 I went directly to the fuse block after an inline fuse. Instead of a big 3 upgrade I did a big like a big 6 or 7 upgrade

Is this how the battery to pdc and alternator to pdc supposed to be?