Durango 160A Alternator Upgrade for XJ 4.0

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Apr 26, 2017 | 05:58 PM
  #1  
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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Jun 6, 2017 | 11:01 AM
  #2  
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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Jun 6, 2017 | 03:51 PM
  #3  
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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Jun 6, 2017 | 06:33 PM
  #4  
I believe a 160a alternator from a ZJ would have worked
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Jun 7, 2017 | 08:22 PM
  #5  
The 160 is only on the V8, right?
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Jun 8, 2017 | 08:30 PM
  #6  
Quote: 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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Jun 8, 2017 | 09:09 PM
  #7  
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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Oct 19, 2022 | 07:09 PM
  #8  
Quote: 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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Oct 19, 2022 | 11:19 PM
  #9  
Quote: 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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