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Durango 160A Alternator Upgrade for XJ 4.0

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Old Apr 26, 2017 | 05:58 PM
  #1  
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Default Durango 160A Alternator Upgrade for XJ 4.0

Hey all,

Looking to do this upgrade that I've heard works but need a little help.

My current alternator looks like this in back with the two lug wires that bolt right in the back:

http://www.autozone.com/batteries-st...11065_940035_0

The back of the 160A Durango alt looks like this with that two prong plug in back:

http://www.autozone.com/batteries-st...84191_938145_0

I found a cable/plug through autozone too:

http://www.autozone.com/electrical-a...tor/518343_0_0

I'm wondering if I can just buy this plug/wire kit, wire it to my XJ in place of the two lug wires I have now, then just plug in the new 160A Durango alt? Anyone done this before? What's all involved in doing the wiring to this plug? Looks like there's 4 wires with that new autozone plug, anyone know what thats about?

Any other suggestions for just getting a different alternator that will fit my current connection?

I know that I'll have to do some grinding and swap pulleys, thats ok with me. I also plan on doing 2AWG wire and a inline megafuse at the pdc.

I did just stumble across a 200A alternator on ebay that has my same connection so I might just go with that. Do I need bigger cables than 2AWG for a 200A alt though, anyone know?

Any and all help will be greatly appreciated.
Thanks,
Steve
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Old Jun 6, 2017 | 11:01 AM
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So after all that waste of time trying to do research on how to make that work, I ended up finding a 165A alt off ebay from Load Boss for nearly same price as a durango alt. Same connection, no grinding or anything, fit right in and seems to work fine so far. They also gave me a test report for the alt with it, saying how many amps its putting it out at what RPM which I thought was kind of cool.
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Old Jun 6, 2017 | 03:51 PM
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Glad to hear you got it fixed. I need to replace my alternator but don't really have the need to upgrade but might as well. Right?
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Old Jun 6, 2017 | 06:33 PM
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I believe a 160a alternator from a ZJ would have worked
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Old Jun 7, 2017 | 08:22 PM
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The 160 is only on the V8, right?
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Old Jun 8, 2017 | 08:30 PM
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Originally Posted by Big David
The 160 is only on the V8, right?
Yeah. I'm not sure if it was all of them or if it was option. I'd have to do some digging.
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Old Jun 8, 2017 | 09:09 PM
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Most are 136 amp off the ZJ and Durango's, some got 160 amp alternators but it might have only been the 5.9L's
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Old Oct 19, 2022 | 07:09 PM
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Originally Posted by steven1000sv
So after all that waste of time trying to do research on how to make that work, I ended up finding a 165A alt off ebay from Load Boss for nearly same price as a durango alt. Same connection, no grinding or anything, fit right in and seems to work fine so far. They also gave me a test report for the alt with it, saying how many amps its putting it out at what RPM which I thought was kind of cool.
what year is your xj? wondering if it’ll fit my 1989
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Old Oct 19, 2022 | 11:19 PM
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Originally Posted by unknownsarg
what year is your xj? wondering if it’ll fit my 1989
Being this thread is 5yrs old, I doubt the user will be here to answer.

This will not work with an 89.
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