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99-03 superduty alternator upgrade??

33K views 39 replies 13 participants last post by  Powastroka  
I had those 200 amp alternator.

My advised is keep stock alternator. They are fine. Problem is factory harness are too small for these demand. They become melt and cause poor contact. Kill batteries in short time.

You need add another ground cable from alternator bolt direct to battery's negative post.
Then tape those factory harness for output positive. Get cable with fuse in middle. Need 100-115 amp fuse. I suggested 2 gauge they are plenty. Put on output stud to battery's postive.
 
Not to start fight.

Reason why alternator go bad. Bad connections, ground issues, bad or weak batteries. There one thread here about guy who went though 7 alternators in short time because he had bad wiring issues. Best part shop didn't test wiring.

I never have replaced alternators on my fleet after I start maintain "CORRECT WAY". Cause I add ground cable from battery to alternator and clean all connections with sand paper. Test with OHM meter.

I can't stress how many fleet from different companies I see still use factory harness for alternator and there tons acid on batteries terminal. Just wait until they start *****y/moan how their 10 trucks broke down so often that related to electric issues.

When I told them test all connections with OHM meter. They say nah it charging FINE. What a IDIOT.