130 Amp Alternator Upgrade

 

By: 94xlt4.0

This is how I installed a 130 amp alternator into my ’90 Bronco 2. therangerstation.com and I are NOT responsible for any damage you do to your vehicle by attempting to recreate this swap.

Things you’ll need:

  • 130 amp alternator from a 3.8 liter V6 Mustang, Thunderbird (non supercharged), Windstar, etc.
  • About 25 inches of 2 or 4 gauge battery cable (2 is better)
  • 140 amp mega fuse
  • female spade terminal
  • alternator bracket from 80’s Chevy 350

Tools needed:

  • socket set
  • wire cutters/ strippers
  • 24mm socket
  • impact wrench or socket wrench for the 24mm socket

Instructions:

NOTE: ALWAYS remove the negative battery cable when doing electrical work.

1. Remove the air intake hose and air box then the alternator belt.

2. Remove the two bolts holding the alternator on as well as the two plugs and remove alternator.

3. Remove the bolt holding the alternator bracket and remove the bracket. New bracket on the left, old bracket on the right.

4. Take the white wire from the rectangle plug and cut it near the plug. Solder the female spade terminal to this wire.

This picture was found on Google by Twister (thanks for the help). I did not move the yellow wire from the regulator plug shown in this pic because it runs to the power distribution box already anyway.

5. Take the 24mm socket and use an impact wrench to remove the nut holding the pulleys to the alternators. Junkyard 130a alternator on the left, old 60 amp alternator on the right

pulley swapped

6. Install the new alternator bracket and the new alternator. Your stock belt should work (mine did)

new alternator installed

7. Take the battery cable and install the mega fuse. (I bolted one end to the post on the starter solenoid and the other end to the battery cable.)

8. Plug in the regulator plug(D shaped plug), stator wire (spade terminal) and attach the battery cable to the post on the back of the alternator.

9. Re-install the air intake hose and the negative battery cable.

Here is the final product:

There is about 1/4 inch between the hose and bracket

There is about 1/2 inch between the alternator and the valve cover

Overall the whole swap took me about and hour start to finish. Before the swap the dash lights would dim if i turned on anything electrical. Now, I can have 2 sets of auxiliary lights, my headlights, my subwoofer and the heater or a/c full blast and there is no dimming at all. I am very happy with the swap and HIGHLY recommend it to anyone with charging issues or any electrical add ons.

Special thanks to Twister for the help with the wiring department.

Resource:

How To: 130 amp alternator in a 2.9