80 series denso jaguar alternator replacement upgrade and/or photoman bracket install

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landcruiser3DP

landcruiser3DP

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i think i need to replace my alternator. it wouldn't start, battery light is on, ABS light comes on and when off, then tech and speedo jump around when i put the flashers on. anyway battery is dead and grounds seem secure so i am thinking it has to be the alternator since its not charging.
has anyone down the jag alternator upgrade? i actually have the photo man adapter but i'm thinking to do this jag option?
anyone done this that can advise and/or keep an eyeball on this thread while i attempt it in case i need a pair of eyeballs with a (mechanical) brain attached?
THANKS
EDIT: forgot to mention i actually have the Photoman larger alternator Kit already but had intended on selling it thinking i wasn't going to use it but now that my alternator took a dump i wonder if i could use that somehow...?

Easy 80 Series 140 amp alternator install

The hardest part of this job was wading through the nonsense on MUD to get to the good stuff. I plan to do this to my other 80 soon before all these alternators sell out. This thread on Mud https://forum.ih8mud.com/threads/possible-bolt-in-140-145a-alternator.960770/page-4#post-14776878...
risingsun4x4club.org risingsun4x4club.org
 
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Dragos80 said:
There is no need for an outside link just to be linked back to Mud.

You can see several options here in this thread. Jag too.

Possible bolt in 140-145a alternator - https://forum.ih8mud.com/threads/possible-bolt-in-140-145a-alternator.960770/
Click to expand...
hey. thanks i just found that thread linked to a mud thread. looks like he posts on page 4 #78. Possible bolt in 140-145a alternator - https://forum.ih8mud.com/threads/possible-bolt-in-140-145a-alternator.960770/page-4#post-14776878
have you done this specific upgrade?
in the thread he seems to swap the pulley from the old alternator to the new alternator (so presumably you can't get a core credit?), enlarge the bolt hole by about 3/8" and then he grinds somewhere for clearance? also i guess he upgrades the wiring (to the starter?)?
and maybe the connections are swapped left to right between this starter and OEM?
the advantage of the original link is it's relatively straightforward so wondering of anyone has done this specific mod with this specific part. and also how it's doing?
i was thinking to order it for $200 and worst comes to worse if i return my OEM instead i would return it?

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Dragos80 said:
Check out landtank's site. He is a member here.

Alternator - https://landtankproducts.com/collections/alternator
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i forgot to mention i actually have the Photoman larger alternator Kit already but had intended on selling it thinking i wasn't going to use it but now that my alternator took a dump i wonder if i could use that somehow...?
obviously i am not up to speed on any of this so just asking in case anyone has ideas.
right now i am thinking to just pull the OEM and run it up and have it refurbished locally and plop it back in...
 
A few folks have done the Jag alternator. I'm on my 2nd one.
1764912691430.webp

The Jag has a larger body that requires trimming of the body and modification to the OEM alternator/belt tension adjuster.
Once modified, the Jag is plug and play.
1764912818758.webp
After modification, the Jag swings and has plenty of adjustment to get he belts on.
1764912931355.webp

The lower mount is a smooth bore and requires a helicoil to be installed as pictured above.

While I was in there, I made a slightly larger fusible link. I don't think this is a necessary step.
1764913049343.webp
 
lumbee1 said:
While I was in there, I made a slightly larger fusible link. I don't think this is a necessary step.
Click to expand...
Just for reference, the blue fusible link is rated at 100 amps and the stock alternator is an 80 amp unit. If you're putting in an alternator that produces 100% more current, all associated wiring must be upgraded to support it, including the fusible link.
 
lumbee1 said:
While I was in there, I made a slightly larger fusible link. I don't think this is a necessary step.
Click to expand...
Out of curiosity, what is the rating of the link you made? I'm having trouble finding that color code.
 
jonheld said:
Out of curiosity, what is the rating of the link you made? I'm having trouble finding that color code.
Click to expand...
10 Gauge Fusible Link Wires, 9" Length, Compatible With GM 12077140
 
lumbee1 said:
A few folks have done the Jag alternator. I'm on my 2nd one.
View attachment 4042532
The Jag has a larger body that requires trimming of the body and modification to the OEM alternator/belt tension adjuster.
Once modified, the Jag is plug and play.
View attachment 4042533After modification, the Jag swings and has plenty of adjustment to get he belts on.
View attachment 4042534
The lower mount is a smooth bore and requires a helicoil to be installed as pictured above.

While I was in there, I made a slightly larger fusible link. I don't think this is a necessary step.
View attachment 4042536
Click to expand...
thanks a lot lumbee. great info.
i ended up pulling mine and ran it up to a rebuild shop here in town. i ended up thinking i need to get it back on the road as soon as possible and also if i remove and reinstall once at least i will know what i am in for ahead of time if i do upgrade.
i will admit to having a hack of a time accessing some od the bolts so for reinstall i picked up a $25 pack of this ratchet style crescent t wrenches. i also forgot to tilt the alternator in at the bottom to loosen belts but after getting some help on the phone i am with the program on that now too.
i tried to save ehe little cup for grommet by not removing it form the housing and thought i could just cut the zip tie portion and use a ew zip tie but not entirely sure what is going to work. also that grey electrical connection eventually came out. i think the release is from pushing in and not from pulling out but anyway i finally go that removed. basically i pulled the alternator and worked the harness once it was having up and easier to get my hands on.

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IMG_9351.webp


IMG_9323.webp
 
not sure if anyone has any tips on this bolt (edit: sorry nut). i think it is 14mm but its so rounded it's almost hard to know. i think i am going to bash a 14mm crescent wrench over it and try to force it off.
i want to clean up on here but also i dont want to leave a rounded off bolt in here.
right now it is soaking in penetrant...

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I thought that was a nut on a stud. The nut is a 12mm not a 14mm. 6 point wrench or socket should do the trick. It's been a while since I removed mine.

Are you replacing your OE alternator tensioner with the photoman?
 
lumbee1 said:
I thought that was a nut on a stud. The nut is a 12mm not a 14mm. 6 point wrench or socket should do the trick. It's been a while since I removed mine.

Are you replacing your OE alternator tensioner with the photoman?
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hey thanks a ton for this.
i'll try 12mm wrench i guess. it's tight in here so i actually picked up a small set of ratcheting wrenches. i'm not totally sure how much pressure i can put on those things since they look like plastic inside. but also i guess i just need to get it loose so ill use a conventional 12mm.
on Photoman alternator adapter i hadn't considered this. it's been sitting around for years now. i got worried he was going to stop swelling it and bought one.
can i install part of it now? i dont think i have the time to buy a new alternator and install a large one now but i could have this as a project down the line and i'm not averse to installing part of this alternator kit now if there is a good reason?
 
landcruiser3DP said:
hey thanks a ton for this.
i'll try 12mm wrench i guess. it's tight in here so i actually picked up a small set of ratcheting wrenches. i'm not totally sure how much pressure i can put on those things since they look like plastic inside. but also i guess i just need to get it loose so ill use a conventional 12mm.
on Photoman alternator adapter i hadn't considered this. it's been sitting around for years now. i got worried he was going to stop swelling it and bought one.
can i install part of it now? i dont think i have the time to buy a new alternator and install a large one now but i could have this as a project down the line and i'm not averse to installing part of this alternator kit now if there is a good reason?
Click to expand...
I hope you got the ratcheting wrenches with the direction selector on them. I had a cheap set of harborfreight ratcheting wrenches with no selector. The 19mm got struck when loosening a spring compressor and there was no way to reverse it to unjam it. Luckily the nut was just tall enough to put another wrench on top of the ratcheting wrench and back it down.

I had another friend that had the same thing happen to him when trying to remove a light from his bumper. No way to reverse it and it became a permanent feature of the bumper.

I modified my bracket to fit the larger Jag alternator. It's been a whilte but if I remember correctly a traditional wrench is what you need. The gap around the nut is too tight for a larger ratcheting wrench. IF you are concerned about getting the cruiser back on the road as soon as possible, then just use the OE bracket and replace it was the photoman at a later date when you have more downtime.
 
lumbee1 said:
I hope you got the ratcheting wrenches with the direction selector on them. I had a cheap set of harborfreight ratcheting wrenches with no selector. The 19mm got struck when loosening a spring compressor and there was no way to reverse it to unjam it. Luckily the nut was just tall enough to put another wrench on top of the ratcheting wrench and back it down.

I had another friend that had the same thing happen to him when trying to remove a light from his bumper. No way to reverse it and it became a permanent feature of the bumper.

I modified my bracket to fit the larger Jag alternator. It's been a whilte but if I remember correctly a traditional wrench is what you need. The gap around the nut is too tight for a larger ratcheting wrench. IF you are concerned about getting the cruiser back on the road as soon as possible, then just use the OE bracket and replace it was the photoman at a later date when you have more downtime.
Click to expand...
hey. again thanks a ton for this.
i corrected the "bolt" mention. i saw it was a nut on a threaded stud but i wanted to be sure i wasn't trying to force something off that shouldn't be forced.
i'll return the ratcheting wrenches. i did see they had a "sidedness" and in all honesty i am not a fan of buying - well i went looking for craftsman and ended up at home depot so it will go back along with the green scrub pads since it turns out i have a ton of those.
so the alternator is not going to come back before tuesday i think (i'm rocking the clapped out hoopdy first gen tacoma) so im just in there cleaning up and getting this nut off.
can i put the photo man alternator on and get any additional utility out of it?
or i guess you are saying i could put that on now and an upgrade to the tundra or sequoia (?) denso (?) alternator would be easier to accomplish? or what please?
 
landcruiser3DP said:
hey. again thanks a ton for this.
i corrected the "bolt" mention. i saw it was a nut on a threaded stud but i wanted to be sure i wasn't trying to force something off that shouldn't be forced.
i'll return the ratcheting wrenches. i did see they had a "sidedness" and in all honesty i am not a fan of buying - well i went looking for craftsman and ended up at home depot so it will go back along with the green scrub pads since it turns out i have a ton of those.
so the alternator is not going to come back before tuesday i think (i'm rocking the clapped out hoopdy first gen tacoma) so im just in there cleaning up and getting this nut off.
can i put the photo man alternator on and get any additional utility out of it?
or i guess you are saying i could put that on now and an upgrade to the tundra or sequoia (?) denso (?) alternator would be easier to accomplish? or what please?
Click to expand...
You've got options:
Leave the OEM bracket, install the rebuilt alternator.
Install the Photoman bracket, install the rebuilt alternator.
Install the Photoman bracket and install the rebuilt alternator, but replace the rebuilt alternator at a later date with a Tundra/Sequoia alternator.
 
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