[Godwin]

After reading the threads on alternator upgrades I began to consider the 130/150 amp Toyota alternator for a different application. I began by purchasing a 130 amp alternator from a 2003 V8 Tundra. Next I ordered an alternator pulley for a 1997 80 series. In reading this thread http://forum.ih8mud.com/80-series-te...r-upgrade.html I kinda glossed over post #4 which indicates that there are two pulleys, one which will not bolt up. As it turned out the one I purchased did not bolt up and it is part # 27411-66040. A good friend has a lathe and yesterday we corrected this situation.

Both the Tundra and FZJ pulleys have a raised base which fits in a shallow cavity in the body of the alternator. This base on the the FZJ pulley is ca. 4 mm too wide and due to the extra width hits the body of the alternator. Alternator cavity width is ca. 30 mm. All we needed to do was remove ca. 4 mm of material from the width of the pulley and it would then drop into the cavity and ride properly on the shaft, or nearly so.

Second difference between the two pulleys was the inner diameter. The Tundra shaft is 15 mm diameter. The FJZ pulley I purchased has an inner diameter of 17 mm. I picked up a brass bushing at the hardware store which had an inner diameter < 15 mm and an outer diameter > 17 mm. We then turned the bushing so that it would fill the space. IOW it then had an inner diameter of ca. 15 mm and was 1 mm thick. The length was 10 mm.

After these modifications the pulley fits. Now will someone post up the part number for the pulley which will fit with no mods?

[concretejungle]

Originally Posted by Godwin

After reading the threads on alternator upgrades I began to consider the 130/150 amp Toyota alternator for a different application. I began by purchasing a 130 amp alternator from a 2003 V8 Tundra. Next I ordered an alternator pulley for a 1997 80 series. In reading this thread http://forum.ih8mud.com/80-series-te...r-upgrade.html I kinda glossed over post #4 which indicates that there are two pulleys, one which will not bolt up. As it turned out the one I purchased did not bolt up and it is part # 27411-66040. A good friend has a lathe and yesterday we corrected this situation.

Both the Tundra and FZJ pulleys have a raised base which fits in a shallow cavity in the body of the alternator. This base on the the FZJ pulley is ca. 4 mm too wide and due to the extra width hits the body of the alternator. Alternator cavity width is ca. 30 mm. All we needed to do was remove ca. 4 mm of material from the width of the pulley and it would then drop into the cavity and ride properly on the shaft, or nearly so.

Second difference between the two pulleys was the inner diameter. The Tundra shaft is 15 mm diameter. The FJZ pulley I purchased has an inner diameter of 17 mm. I picked up a brass bushing at the hardware store which had an inner diameter < 15 mm and an outer diameter > 17 mm. We then turned the bushing so that it would fill the space. IOW it then had an inner diameter of ca. 15 mm and was 1 mm thick. The length was 10 mm.

After these modifications the pulley fits. Now will someone post up the part number for the pulley which will fit with no mods?

Good post and great info to know. I have the bracket from photoman to adapt this alternator and plan on this coming summer. I figured the pulley on the upgraded alternator worked without messing with it. I'll be interested to see what others say.

[Photoman]

The high output alternators I have both have a 17MM shaft, the same as a stock 1997 Fzj80. The alternator numbers are 27060-0F040 for the 130 amp and 27060-0F050 for the 150 amp. The stock 1997 Fzj80 alternator number is 27060-66070. HTH

Sorry for the hijack but I put up a page with some guidelines and pictures for the bracket install here.

Bill

[Godwin]

Part number from the alternator that I used is 27060-50300. Thanks for posting the other numbers.

This alternator will be going onto a 2F in place of the smog pump using the stock bracketry with very minor modifications.