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Alternator Upgrade/Relocation

Old 05-12-2019, 07:11 AM
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Default Alternator Upgrade/Relocation

First use of my winch the other day, not as practice but to actually self recover from a bad mud hole. Winch performed well, itís a Warn VR8-S, but it really overloaded my electrical system after a period of time. Pulling really slow , headlights dimming, etc.

Now itís time to upgrade with a higher output alternator and better battery, maybe even a dual battery setup. Iíd also like to delete the A/C and mount the alternator there.

I recall seeing a writeup on here with all the details, including new serpentine belt length, but I canít find it now. Anyone have that link?

Thank you!


Couldnít pull it out backwards.


Yep, lots of digging.


Finally pulled myself forward and to the right, but it really taxed my stock electrical system after a while.
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Old 05-12-2019, 08:24 AM
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Dual batteries will help more than the alternator. So will upgraded cables. Were you using a ****** block?
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Old 05-12-2019, 10:21 AM
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A 160 amp Durango alternator can be mounted in the stock location if you grind the bracket. And as stated upgrade your cables. A member here sells sets.
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Old 05-12-2019, 11:09 AM
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Originally Posted by BlackXJay View Post
A 160 amp Durango alternator can be mounted in the stock location if you grind the bracket. And as stated upgrade your cables. A member here sells sets.
Been doing some research on this. Appears you have to take the block down a little too.
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Old 05-12-2019, 11:23 AM
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I did not have to grind the block. But I have heard of people that did. I also bought a extra bracket off ebay. Only 25$

https://rover.ebay.com/rover/0/0/0?m...2F303134323372

I purchased the alternator and ground the bracket before installing. Just incase something went wrong with the original bracket. If you have no down time this is the way to go.
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Old 05-12-2019, 11:25 AM
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Oh and swap pulleys from yours to the Durango one if you go this route.
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Old 05-12-2019, 03:49 PM
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Originally Posted by cruiser54 View Post
Dual batteries will help more than the alternator. So will upgraded cables. Were you using a ****** block?
Cruiser, I was using a ****** block, and it exploded. Not sure if somehow it was my fault, as I couldnít see it at the time and my helper knows nothing about much at all and Iím sure wasnít paying attention. ****** block was attached to a span set around a tree, I ran my winch rope through the ****** block and anchored it back to my front bumper. As far as I know that should have given me a 2:1, but I was dug into the mud deep at that point. Iím just glad no one got hurt and there wasnít additional damage.


The parts I found.



C-clip still intact on the other side.



This is the side that failed. C-clip is missing, outer spindle flange is broken off.
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Old 05-12-2019, 04:11 PM
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Nothing you did. What brand ****** block?
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Old 05-12-2019, 05:10 PM
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Originally Posted by cruiser54 View Post
Nothing you did. What brand ****** block?
Purchased online from Vault Cargo Management. No capacities stamped on it.
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Old 05-12-2019, 05:15 PM
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Originally Posted by ElMartillo View Post
Purchased online from Vault Cargo Management. No capacities stamped on it.

What is the winch rated at?
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Old 05-12-2019, 07:21 PM
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Originally Posted by cruiser54 View Post
What is the winch rated at?
8,000 lbs.
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Old 05-12-2019, 10:42 PM
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Originally Posted by ElMartillo View Post
8,000 lbs.
How do you have it wired? What gauge wire and from where?
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Old 05-16-2019, 07:45 PM
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Originally Posted by cruiser54 View Post
How do you have it wired? What gauge wire and from where?
Wired as per factory instructions, though because of the design of my bumper I had to extend the cables to mount the control box in the engine compartment. I used 4ga cable, with the lugs soldered and swaged correctly.

I still want to relocate the alt to the A/C compressor position though, and from what I understand it doesnít hurt to put in a higher output alternator.
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Old 05-17-2019, 10:11 AM
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Old 05-17-2019, 12:10 PM
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Originally Posted by WyoCherokee View Post
You are installing in a Ď90 MJ? Wondering if it will work in my Ď89 XJ? Also, stock alt or higher output?
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