4.0L OHV Soul crushed and seeking advice on starting problems

[SenorNoob]

My 91 harness plugged right into a 130A from a later (99? 03? I don't remember) Explorer. It is a shorter case so the rear mount bolt isn't in but the 2 front has worked fine for about 8 years now... There was one single wire not used by the newer alternator.

 

[TacoBelleGirl]

Weird I thought they were completely different generations of alternators and needed wiring adapters. Well I'll have to order an alternator regardless so I'll update

 

[SenorNoob]

I did just remember one other oddity. My belt was on the long side of working and the newer 130A had a slightly (2mm) smaller pulley. So I ended up replacing the belt at the same time. That's how I found out that all of Oreilly's stock belts at that time were 1/2 longer than Ford specs.

 

[SenorNoob]

A quick googling says 96+ has the thinner case. I also don't see any options for 130A in the earlier style immediately. That's likely why I did mine like that.

Edit: Here is one. https://www.ebay.com/itm/380356706014

 

[TacoBelleGirl]

I had read that the SOHC explorer and rangers had different alternator mounting.. I wonder if you would have had better luck with a ranger alternator.
I just ordered a shiny new ACDELCO Gold 130 amp alternator for a 96 Ranger.

https://www.rockauto.com/en/moreinfo.php?pk=3467928&cc=1138104&pt=2412&jsn=809

 

[SenorNoob]

That makes sense. Packed things tighter to make room for the cams. It's serving me well so far...

 

[bobbywalter]

 

[mtnrgr]

You should be good with installing a 130 amplifier alternator on your 91 4.0. There should be 2 plugs on there. One with 2 or 3 wires and one with a single wire..and the other wire that bolts on there from the battery. I can't say for sure how the ohv and sohc engines are. Make sure its for the ohv engine.

I looked after some pictures to verify this, go ahead and put one on there.

Around 27 years ago, i installed a 130 amp from a 97 Explorer i bought used as i did a very powerful audio setup in my 94 3.0 5spd ranger with no modifications. The plugs fit right in. I started upgrading all power wire and ground wires with all 4 gauge inside engine compartment Battery to alternator,. battery to radiator support, engine to frame, engine block to firewall..i did other 4 gauge wire upgrades in other areas. That alternator lasted 10 years..without any issues. In 2010 I went to the yard again and found a used oem one from a 99 Explorer and had it tested a couple of times at the auto store and it tested very strong. When my 94 3.0 ranger was totaled last summer it still had that same alternator in there.

Was is your battery size in your 91? If battery is two small with stock wiring it may not be able to keep that 130 working like it should..fro. my experience I've seen, can't say about others. If you buy a new or rebuilt one..have it tested prior to installing it. Here's a couple of pictures from my old ranger with 130 and maybe see the wiring upgrades.

I was also using a very large motorcraft battery.

 

[bobbywalter]

You should be good with installing a 130 amplifier alternator on your 91 4.0. There should be 2 plugs on there. One with 2 or 3 wires and one with a single wire..and the other wire that bolts on there from the battery. I can't say for sure how the ohv and sohc engines are. Make sure its for the ohv engine.

I looked after some pictures to verify this, go ahead and put one on there.

Around 27 years ago, i installed a 130 amp from a 97 Explorer i bought used as i did a very powerful audio setup in my 94 3.0 5spd ranger with no modifications. The plugs fit right in. I started upgrading all power wire and ground wires with all 4 gauge inside engine compartment Battery to alternator,. battery to radiator support, engine to frame, engine block to firewall..i did other 4 gauge wire upgrades in other areas. That alternator lasted 10 years..without any issues. In 2010 I went to the yard again and found a used oem one from a 99 Explorer and had it tested a couple of times at the auto store and it tested very strong. When my 94 3.0 ranger was totaled last summer it still had that same alternator in there.

Was is your battery size in your 91? If battery is two small with stock wiring it may not be able to keep that 130 working like it should..fro. my experience I've seen, can't say about others. If you buy a new or rebuilt one..have it tested prior to installing it. Here's a couple of pictures from my old ranger with 130 and maybe see the wiring upgrades.

I was also using a very large motorcraft battery.

nice work there

 

[TacoBelleGirl]

You should be good with installing a 130 amplifier alternator on your 91 4.0. There should be 2 plugs on there. One with 2 or 3 wires and one with a single wire..and the other wire that bolts on there from the battery. I can't say for sure how the ohv and sohc engines are. Make sure its for the ohv engine.

I looked after some pictures to verify this, go ahead and put one on there.

Around 27 years ago, i installed a 130 amp from a 97 Explorer i bought used as i did a very powerful audio setup in my 94 3.0 5spd ranger with no modifications. The plugs fit right in. I started upgrading all power wire and ground wires with all 4 gauge inside engine compartment Battery to alternator,. battery to radiator support, engine to frame, engine block to firewall..i did other 4 gauge wire upgrades in other areas. That alternator lasted 10 years..without any issues. In 2010 I went to the yard again and found a used oem one from a 99 Explorer and had it tested a couple of times at the auto store and it tested very strong. When my 94 3.0 ranger was totaled last summer it still had that same alternator in there.

Was is your battery size in your 91? If battery is two small with stock wiring it may not be able to keep that 130 working like it should..fro. my experience I've seen, can't say about others. If you buy a new or rebuilt one..have it tested prior to installing it. Here's a couple of pictures from my old ranger with 130 and maybe see the wiring upgrades.

I was also using a very large motorcraft battery.

Looked like a really clean truck in those pictures!
Thanks for the added info. The one I ordered was for a 96 so it should be for an OHV if I'm not mistaken.
I also ordered a 4 gauge wire to go between the alternator and the fender post but I didn't consider that I may need bigger cables back to the battery itself. These are all new OEM-Style sets I had installed some months back

The battery is an 850ACC that's one year old. If memory serves me correctly I purchased it the same month it was manufactured.
I always try to over-spec my batteries when I buy them and I don't want issues with the truck so I sought out the most CCAs and what I believe to be the biggest battery I can fit in the stock location.

 

[lil_Blue_Ford]

Looked like a really clean truck in those pictures!
Thanks for the added info. The one I ordered was for a 96 so it should be for an OHV if I'm not mistaken.
I also ordered a 4 gauge wire to go between the alternator and the fender post but I didn't consider that I may need bigger cables back to the battery itself. These are all new OEM-Style sets I had installed some months back

The battery is an 850ACC that's one year old. If memory serves me correctly I purchased it the same month it was manufactured.
I always try to over-spec my batteries when I buy them and I don't want issues with the truck so I sought out the most CCAs and what I believe to be the biggest battery I can fit in the stock location.
View attachment 147776

The factory set should have a 4-gauge from the battery to the solenoid post, that’s adequate.

That is a 65 series battery, which is what I try to put in most of my stuff. Actually swapped an Explorer battery tray into my 00 green Ranger so I could stuff a 65 series into that. Even with the bigger tray (98-11 Rangers have a tray too small for a 65 series), I had to kinda shoehorn it in. Like you, I prefer the bigger battery. The only truck I still haven’t modified is my blue Ranger. Plus my F-series also use a 65 series. It’s nice to have interchangeable batteries.

 

[mtnrgr]

Looked like a really clean truck in those pictures!
Thanks for the added info. The one I ordered was for a 96 so it should be for an OHV if I'm not mistaken.
I also ordered a 4 gauge wire to go between the alternator and the fender post but I didn't consider that I may need bigger cables back to the battery itself. These are all new OEM-Style sets I had installed some months back

The battery is an 850ACC that's one year old. If memory serves me correctly I purchased it the same month it was manufactured.
I always try to over-spec my batteries when I buy them and I don't want issues with the truck so I sought out the most CCAs and what I believe to be the biggest battery I can fit in the stock location.
View attachment 147776

Thanks, I had that truck for 31 years. I purchased it new in 94. A stock 2wd ranger. I built that truck from the ground up, and did 97% of the work on it. I of course had some assistance from those who i knew in the auto industry on many levels. No shady of anykind built that truck for my needs to how I used it, and got to many places it never should went, yet it did everything I put it thru.

It killed me when he was taken away last year from my hands..my Ole friend, that truck had 653,370 miles, saw 45 states and ALOT more places.

Here is a picture of it last spring. Don't let the cleanliness fool you..this truck saw endless desert, mountains terrains, covered in snow, mud, dirt, sand..it always made me smile.

This was at mt Lassen last spring.

 

[TacoBelleGirl]

The factory set should have a 4-gauge from the battery to the solenoid post, that’s adequate.

That is a 65 series battery, which is what I try to put in most of my stuff. Actually swapped an Explorer battery tray into my 00 green Ranger so I could stuff a 65 series into that. Even with the bigger tray (98-11 Rangers have a tray too small for a 65 series), I had to kinda shoehorn it in. Like you, I prefer the bigger battery. The only truck I still haven’t modified is my blue Ranger. Plus my F-series also use a 65 series. It’s nice to have interchangeable batteries.

Okay great! I just got the new alternator and that cable should be here on Friday.
Not sure if this thing is made in china or the USA lol

Thanks, I had that truck for 31 years. I purchased it new in 94. A stock 2wd ranger. I built that truck from the ground up, and did 97% of the work on it. I of course had some assistance from those who i knew in the auto industry on many levels. No shady of anykind built that truck for my needs to how I used it, and got to many places it never should went, yet it did everything I put it thru.

It killed me when he was taken away last year from my hands..my Ole friend, that truck had 653,370 miles, saw 45 states and ALOT more places.

Here is a picture of it last spring. Don't let the cleanliness fool you..this truck saw endless desert, mountains terrains, covered in snow, mud, dirt, sand..it always made me smile.

This was at mt Lassen last spring.

You obviously loved that truck to keep it looking that clean and get it to 653,370 miles! Was that mostly all highway?
I assume you had good insurance on it, but they probably still didn't give you anywhere near enough. What a loss

 

[rubydist]

Their packaging and labeling is working - they want you to think it might be made in the USA but it is really made in China and it is made for AC Delco which is in Michigan.

 

[TacoBelleGirl]

Alright well small update for y'all:
I drove the truck today for probably roughly 3 hours and around 80-100 miles with probably around a half hour total of idle time too, maybe a touch longer with one significant one.

The first half of the drive I was seeing signs that the alternator was struggling and that was indeed with the fan hooked up.. Which worked out because I was headed to my friend's place with the new alternator ready to go in.
I do not have pics, but it went in essentially as-if it was stock. I did not have to change the belt or swap the pulley and all 3 bolts lined up perfectly so I can safely recommend a 130amp from a 96 4.0 to go into an older year. The one plug you all mentioned plugged right in and we ran our 4 gauge wire between the battery and the positive post on fender-mounted solenoid.
I think the cable that goes back to the battery is only a 6 gauge though..
Anywho fired up and had 14 volts and it seems to handle loads a lot better than the old one did which is much to be expected.

Back to the drive..
I mostly kept kept it under 60 for fuel economy.. that's abound 3500 RPM and overall I had minimal issues, especially with the new alternator.
Driving home I was able to have the radio, efan, and brights on with no issue.
Having said all that...
I still have the same problem that I have had literally from day one with this truck. If you get it hot and turn it off, it just does not want to start. Takes a lot of cranking over which my setup really doesn't enjoy..
And then once or twice while cruising on the highway I have felt a momentarily loss in power to the wheels. This was something I noticed starting right before I did all the recent work to it, but it is a new problem when compared to the year before.


For temps they seem perfect when cruising, and not staying mobile, but when sitting idle for awhile it creeps up a little bit. Idling in a very slow drive thru for about 10-15mins it seemed to settle around the L on the gauge. I don't think the fan is cycling on and off or anything... I think that's just the level of cooling that is currently on tap without moving.
More stuff to figure out, it's a project