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Question about alternator upgrade - wiring
#1104919
03/18/19 10:53 PM
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Joined: Nov 2013
Posts: 93
OP
Getting the Wheeling Fever
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I’m preparing to drop in a Starion 75-amp alternator in place of the 50-amp unit in my ’87 4-cyl. However, I’ve been looking at the charging wire running from the alternator, and it’s a pitiful thing; I haven’t measured the conductor to be sure, but it looks like no more than a 10-gauge wire.
Looking at wiring charts, it tells me that a 5-foot run (which is about what it is from the alt to the battery) at 75-amps requires a 4-gauge wire. That’s a big difference from what’s in there!
Should I upgrade that stock wire before putting the new alternator in?
1987 Montero SWB, 2.6L, 5spd Weber conversion 2-valve head from Engine Machine Service "4G54 FTW!"
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Re: Question about alternator upgrade - wiring
[Re: GrantCee]
#1104920
03/21/19 02:02 PM
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Joined: Oct 2018
Posts: 79
Getting the Wheeling Fever
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What little I've learned from restoring motorcycles and working on cars for 30 years is, manufacturers do not put more than what is needed in their electrical systems, because on a production scale adding $0.10 to the cost of a single wire gets very expensive when they build thousands of them in a month. In other words, the original wire was probably barely sufficient for the OEM 50-amp current, in addition to being 30 years old and having decayed in that time, you should upgrade it.
1989 Dodge Raider V6 2001 Jeep Wrangler 4.0L 2008 Toyota 4-Runner SR5 4wd
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Re: Question about alternator upgrade - wiring
[Re: Bigshankhank]
#1104921
03/22/19 08:13 PM
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Joined: Nov 2013
Posts: 93
OP
Getting the Wheeling Fever
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What little I've learned from restoring motorcycles and working on cars for 30 years is, manufacturers do not put more than what is needed in their electrical systems, because on a production scale adding $0.10 to the cost of a single wire gets very expensive when they build thousands of them in a month. In other words, the original wire was probably barely sufficient for the OEM 50-amp current, in addition to being 30 years old and having decayed in that time, you should upgrade it. I've decided to replace that wire with a 4-ga wire and a slow-blow ANL fuse. That should cover everything.
1987 Montero SWB, 2.6L, 5spd Weber conversion 2-valve head from Engine Machine Service "4G54 FTW!"
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