150 Amp Alternator - Thanks Photoman

Otamiway · Feb 27, 2012

Let me start my thanking Bill - Photoman for 2 excellent products and detailed instructions. :clap:

Orignal write up by Bill -

https://forum.ih8mud.com/80-series-tech/206807-upgrading-stock-alternator-130-150-amp.html

Smaller Pulley write up -

https://forum.ih8mud.com/80-series-tech/557272-small-alternator-pulley.html

After sitting on Bill brackets for more than 2yrs, I picked up the smaller pulley that he is making now.

I have to point out that the smaller pulley made installing the belts a lot easier.

NOTE: Follow the bracket instructions carefully, it will stop you from doing this

Step 1

Get alternator from appropriate Sequioa. I got mine from a 2006 shipped to me for under $100 bucks. Toyota P/N 27060 - 0F050

I opted to replace the Alternator brush since they were under $20 and require pulling 3 bolts on the back of the Alternator and 2 screws holding the brush assenbly.

Otamiway · Feb 27, 2012

Step 2 - Install Smaller Pulley

It was really easy to take off and install the Pulley... Air gun and a Torx stick made quick work of it

Otamiway · Feb 27, 2012

Step 3

Take out old alternator.

Remove battery and Battery Tray.

Take the 3 PS reservoir bolts out and move reservoir back out of the way.

Remove coil wire from Cap.

Remove battery wire from alternator, unplug connector and the connector above the alternator.. they are all in the same harness.

Follow FSM on how to remove alternator.

Otamiway · Feb 27, 2012

Step 4 - Connector

Photoman does a great job of explaing how to change the connector.

To dismantle the orginal plug.. Remove the plastic insert and then with a pick tool the remove each lead.

Follow instruction to slide them, into the new plug.

Solid Taco · Feb 27, 2012

Subscribed. I, too have been sitting on my brackets for a while. Might have to do this soon.

Otamiway · Feb 27, 2012

Step 5 - Bracket adjustment

When installing the new alternator, you have to ensure that the bushing in the Bracket on the motor is pushed out fully. I tried tapping it out but with little sucess. I devised a simple solution... A stud, a wrench larger than the bushing. Couple of turns and it eases the bushing out enaough to clear the new alternator.

EDIT------- Photoman now includes a tool to do this..https://forum.ih8mud.com/attachment.php?attachmentid=608468&stc=1&d=1331252743

Otamiway · Feb 27, 2012

Step 6 - Install Bracket & Alternator

Again, cant stress how easy Bills instruction were to use to install the bracket and the alternator. Dont forget to use RTV on the bracket bolts.

Dont forget to slide the belts over the pulley before sliding it into place. With the smaller pulley your are able to do this after you have the top pulley bolt in place.

The shorter adjustment bolt that came with the smaller pulley was an excellent touch. Again Bills attention to detail is great.

Be sure to tension the belt properly the tighten all the necessary bolts - Top bolt, silder bolt and new bottom bolt.

Dont forget to plug back in all plugs, attached the positve cable, re-install the PS reservoir.

Reinstall the Battery box and Bettery.

Double check all you connections and bolts and you are ready to start.

Otamiway · Feb 27, 2012

Only follow up I have it that my 1/0 Guage wire upgrade does not fit.

https://forum.ih8mud.com/80-series-tech/539225-fzj80-cable-upgrade.html

The new alternator bolt was too short for me to bolt both the factory battery wire and my upgraded wire.

I will have to see if i can get a thinner 1/0 terminal to fit it.

Riad · Feb 28, 2012

Ordered the bracket, connector and pulley from Bill yesterday. I think I'm just gonna buy a Denso 150 amp alternator (2007 sequoia) and run with it. What I am concerned about is this, will the system start blowing fuse(es) or bulbs because of the extra/added juice? Or what I should watch out for electrically (other than normal stuff like making sure all grounds are bolted right and etc)?

Thanks :cheers:

Otamiway · Feb 28, 2012

Riad.... You should NOT have to worry about addition juice.. Always a god idea to check you grounds. In my cable thread above, I replaced all the factory grounds with larger and better cables.

Otamiway · Feb 28, 2012

Upgraded Cable

I am working with Mark(FourRunner) redesign my upgrade alternator cable to fit the new alternator.

Need to get a thinner terminal on my 1/0 cable

Pic 1 blurry pic of the factory cable on the new alternator
Pic 2 Pic of the new lead on the old alternator

Photoman · Mar 8, 2012

Thanks for the nice write up and great pictures explaining the process. That's an ingenious solution for a bushing puller.
If it helps, one of many solutions to get past the large terminal at the alternator is to make up a wire from the new fuse and connect up at the lug in the AM1 box. Then insulate the old alternator "B" connector and leave it disconnected from the alternator.

Bill

Otamiway said:
Only follow up I have it that my 1/0 Guage wire upgrade does not fit.

https://forum.ih8mud.com/80-series-tech/539225-fzj80-cable-upgrade.html

The new alternator bolt was too short for me to bolt both the factory battery wire and my upgraded wire.

I will have to see if i can get a thinner 1/0 terminal to fit it.

Otamiway · Mar 8, 2012

McMaster Carr Terminal Lug

That is a good idea, thanks for the suggestions. I am pondering using a "Dual Wire, One Mounting Hole" Termnal Lug from McMaster Carr

McMaster-Carr

I would cut the terminal off the Original "B" wire and the upgraded cable. Once I bolt eachcable into the New Block, I would use heat srink to insulated it and then bolt it to the alternator

Otamiway · Mar 8, 2012

Lug

Actual picture

Photoman · Mar 8, 2012

If you are considering cutting the original terminal "B" lug off then here is another thought. When you cut the lug off there should be 2 wires in the lug. The only one that has to be connected to alternator "B" is the smaller one. The other old wire that goes from the alternator "B" to AM1 is not needed since you ran a new charging wire. The smaller wire might fit on the "B" with the new wiring lug using a smaller ring terminal. Or, it could be crimped in along with a new single lug replacing the extra large one on the new wire.

Bill

Otamiway · Mar 8, 2012

Bill,

Thank you for the info...I will definately have to consider that option...

Stu

stockfj80 · Mar 8, 2012

Pardon my ignorance but I read it one of the older threads by Photoman (Bill) is no longer making the alternator bracket. Is there anyway for me to get a hold of one for my 93'?

Photoman · Mar 9, 2012

I can fix you up with a bracket if you want one. You can PM me.

Bill

stockfj80 said:
Pardon my ignorance but I read it one of the older threads by Photoman (Bill) is no longer making the alternator bracket. Is there anyway for me to get a hold of one for my 93'?

BenMara · Mar 11, 2012

Otamiway said:
I am working with Mark(FourRunner) redesign my upgrade alternator cable to fit the new alternator.

Need to get a thinner terminal on my 1/0 cable

Pic 1 blurry pic of the factory cable on the new alternator
Pic 2 Pic of the new lead on the old alternator

Any word to fix this problem?

Tools R Us · Mar 11, 2012

BenMara said:
Any word to fix this problem?

Easy, just switch to a more reasonably sized wire. :hillbilly:

What size was the wire on the Sequoia that the alt came out of? The run to the battery is only 2-3', so 10G would likely work, 8G would be better, 6G overkill?

150 Amp Alternator - Thanks Photoman

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