http://www.cherokeetalk.com/forum/f2...ee-pics-19987/


I did this swap last night. I'd write another thread but its hard on a iPhone. So enjoy.

 

I'm sorry to mention this, and I read your write up. (very nice) But you are aware that Chrysler offered Higher Amp alternators. That are a direct fit. Here is the option designation code for my 130 amp factory alternator. In 1991 ( Part of their winter PKG., Which included Extra insulation& larger battery ) BAFP 130 Amp Alternator (off org. build sheet)

 

Good to know that lol. I never knew such a thing. Even when I worked at advance auto with the cross references and everything that never caught my eye

 

I'm going to have to do this swap my alternator is new but cannot keep up. I looked in to the stock xj 130 amp and found the part number but no one could order it for me so i went with 90 amp.

 

Denso alternators can be had up to 160A, COTS/OEM. I've posted lists for potential donors.

However, know that if you're crossing the 117A/136A line (I believe 120A is the same frame size as the 117A,) then you'll need to do some clearance work on the OEM bracketry, as the case got larger crossing that line. You end up removing about 1/4" of material from the mounting area (if you're going to use the same stone or burr to work on the iron and aluminum, make sure to load it up with cheap bar soap - frequently! - when working with the aluminum! Aluminum gives a stringy chip that tends to clog things, the soap fills the gaps in the tool so the aluminum does not. The soap gets cleared from the tool, which is why it needs to be reloaded. Often.)

A little more work would be required to adapt a Bosch alternator, and know that the later ND alternators used a two pole plug to attach the field coils (vice the earlier double M4 stud.) The alternator side of that plug will accept a 1/4" spade-style QD, so the wiring may be adapted easily.

Going past 160A means aftermarket parts.

Don't forget - a significant upgrade to the alternator (or even a smaller upgrade, if you're really going to use it!) should be accompanied by upgrading the mains wiring. Also note that the alternator output lead is fused from the factory (either with discrete fuses or with a section of fusible link wire,) and this fuse protection should be restored if that lead is modified (and upgraded to reflect the increased capacity.) MEGA fuses or ANL fuses are commonly used for this, and available in suitable ratings (ANL 60-600A, and I believe MEGA fuses can be had 100-1,000A.)