I know this topic has been discussed many times but what is the best alternator upgrade that can be installed with minimal modifications? I have read about the ZJ, Durango, and Dodge 5.9 alternators being put on an XJ, but which one is the easiest to do? I plan on adding a winch, two 100w KC Daylighters and some other led lights in the future.

 

I did a 136 amp Durango alternator with 4 awg main wiring from 5-90 (what happened to him?) with just a bit of grinding. Check the link in my sig for details. I think its not much harder to do a 160 amp from a Durango or ZJ.

 

I also used a 136 amp alternator from a Durango (rebuilt/rewound to ~150 amp)

You need to grind the alternator bracket a bit, and a little bit of the engine block. Neither is enough material to be sketchy, my cheap harbor freight grinder handled it no problem.

Check this thread for more info;
https://www.cherokeeforum.com/f67/20...or-swap-113268


At the same time, you will want to put in a #4 or larger gauge of wire from the alternator positive to the battery positive, the stock 8ga wire isn't really up to the task of any heavy duty components. I would actually just recommend doing the "big 3" wiring upgrade at the same time or buying a pre-made kit like these;
http://meanlemons.com/index.php/products-2/products/

I made my own, but I would just buy some pre-made ones from XJWonders (mean-lemons). Easier and probably only a few bucks more all said and done.

 

Where is the fuse located that you need to change when you do the wiring upgrades?

 

I have been finding stock replacement alternators that are rated at 136 amps, wouldn't that be the same as using a Durango or V8 ZJ 136 amp alternator? Is there a reason to go with the ZJ alternator when I can just get a stock replacement 136 amp alternator?

 

Have to ask. Have you upgraded your cables yet?

 

Not yet I will be doing that at the same time I change the alternator.

 

I am having a guy rebuild a stock alt. Thinks he can get as much as 150 amps out of it. Grabbed one for free out of the boneyard and probably be $150 to get it done. I am doing it this way cause I want straight bolt in. I know grinding the bracket and/or alt is not a big deal but I still don't want to. Figure that and battery cable upgrade and I am good to go.

 

My current alternator has been working intermittently, sometimes I start it up and it works fine, and other times I will start it up and the voltage gauge on the dash will read 11-12.5 volts (also checked with a meter) then it will drop down to 9 when driving. If I drive it a few miles with the gauge on 9 volts then check with a meter again it will read 13.5-14 volts like normal but the gauge will still be showing 9 volts, if I turn it off and turn the key back on the gauge will read normal again. At first I thought the gauge might be going bad but I swapped in a different, gauge cluster, and checked all the plugs and connections under the dash and it still does the same thing.

 

There was a 136 amp alternator available for 1997 & 1998 XJs, so no modification required. See the replacement part here:

https://www.rockauto.com/en/catalog/...generator,2412

 

Unfortunately they don't fit or make a 136 amp one that fits a '99 to 01. I am guessing it is just a connector thing but I just want a straight bolt in.

 

Yes, from what I understand they will work with slight wiring modifications.

 

I put in a Durango 160A unit, ACDelco 334-1446.

It's got an extra pulley groove, and does take some bracket grinding, but its otherwise a pretty easy bolt it, and works just fine (and uses the same plug on my 2001).

I was lucky and nabbed it off Amazon for $115, it's a $200+ alternator.

 

I decided to go with the Autozone 136 amp alternator. It was supposed to be a factory replacement but I still had to do quite a bit of grinding on the bracket to make it fit, It is in and working fine now.

 

Got your upgraded cables yet?