I am trying to make a 97 zj v8 alternator in my 91 xj... Does anyone have any tips of threads on how to do this? Any help is great!
Ive heard about people doing this but never actually saw it done.

 

1. Go to a junkyard and pick up another XJ alternator bracket (both pieces)
2. Get a good grinder
3. Do this:









4. Swap cable boots off the back of the alternator (ZJ goes the wrong way)
5. Swap brackets/alternators

Also - the alternator you want is the Denso ending with 7913. This is important because not every V8 ZJ has the 136A unit. 97+ is when it was used. My local pick n'pull has about 10 V8 ZJs and only 3 have the 136A unit on them.

 

Moved to Advanced Tech.

 

Is it possible to do this kind of swap on to a 1990 renix?

 

I just got a custom built 160A alt using a Grand Cherokee case. all connections are the same. I started working on mine last night.

thread I am following:
http://www.jeepforum.com/forum/f11/5...1/#post6112672

some pics from my comparisons

larger on left...obviously



you can also see the difference in the mount areas:


where the larger case is not setting in the mount properly:

 

Looks fairly easy to modify so it will fit.

 

this swap is super easy, installed a new one from oreilleys on my 97 and spent maybe an hour taking old one out, grinding, new one in. easy. I don't know why people tell you to grab another XJ bracket, i just used the one that is on my XJ. i'm about to do the same for my 90 and 87.

 

Because the bracket cost me $5 and I was able to do all the mockups/modifications without having to take my Jeep out of service. I also have my original bracket intact should I ever need/want to switch back.

 

out of service for one hour? lol

 

Some people don't have any other vehicle, so if anything goes wrong, their effed.

I remember there was a time like that in my life. And its not fun. Kinda stressful, to be honest. But you make do with what you've got.

 

I'm happy to see this all noted. I have to be 101% sure when I roll my windows up.

 

As an update to this - I went to install my alternator the other night and found there is some grinding needed on the side of the timing cover as well. It is minimal however. I haven't done it yet so I can't give more specifics BUT with the top bolt in the bottom bolt doesn't quite grab the threads. Shouldn't need more than to be hit with a sanding disk on a die grinder.

 

Is this true??? Anyone else experience this? Im doing this mod soon

Also putting the smaller pulley on is a mod in its own. It will increase amps at lower rpms. At the expense of alt life. My last one lasted 3 years like that. Not to bad in the car audio world.

 

Can you talk a bit more about the smaller pulley? Which do you use? How much smaller?

 

It was a general statement, I did it on my last car. I havent got my zj alt yet but, I thought the original xj alt has a smaller pulley? If so I would use it instead of the zj pulley. If not I would search online for a place that sells them. Basically your alternator will be spinning faster bringing you closer to the peak amps at lower RPM's. It doesn't necessarily make it die faster, tho. It's worth it.