I've heard the alternator out of Dodge's 5.9L Durangos can be swapped with the Nippondenso unit fount on later model XJ's, but does anyone know if the Durango 4.7L alternator will work? AutoZone's part details says they both have a 128mm casing...

 

No one? OK, how about this: for those of you that have done the alternator swap from the ZJ, how far off were the mounting bolts before you had to grind down the bracket to fit it? I'm about 1/2" off with this 4.7L Durango alternator.

 

Well, I didn't get any responses so I went ahead and tried it. You'll have to remove quite a bit of material. I went all the way to the threads so I'm having the bracket tack-welded in place- though the insertion of the larger alternator casing is near impossible without undoing the bracket... Nonetheless, I had this alternator upwound to 200amps and now any electrical load I add doesn't bog the engine. I'm a little nervous about having removed the mounting threads (though there are still two more that bolt directly to the block) but I was able to torque them to spec.

 

I hope you are successful, I really want to do this one day. did you buy a brand new alternator? pt#?
are you upgrading your wires? where did you get it upwound?

 

The alternator came out of a 2003 Dodge Durango 4.7L.
I just finished soldering & shrink-tubing a new set of wires with 1awg welding cable.
Denver Generator Exchange did the upwind. Those guys are run a diligent, quality business. I'd rather support local business than the other guys who use cash to paint their alternators green.