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I would not copy that pulley… totally wrong groove profile for the belt width.
The OEM pulley doesn’t fit that alternator?!
Alternator altering
- Thread starter Maina
- Start date
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The OEM pulley doesn’t fit that alternator?!
On the 80 alternator I got, the pulley is very thin where it bolts to the shaft. It’s the same shiny dual row one seen above. The 60 pulley is thicker where the nut clamps down and it doesn’t leave you with enough threads to secure it. I ended up with a pulley from the local old school automotive electrical shop.
Anybody have an interest in a bracket that solves the tensioning issue where you run out of travel? It would let you keep the stock size belt, have plenty of room for tensioning, and you could swap back to the 2F alternator any time. The bracket swaps with one accessible bolt into the block.
I posted some more info about it here. I have a prototype on the way. It does not solve the pigtail or pulley issues obviously.
2007 I tried using a Tundra alternator in the smog pump location. Some info here regarding the pulley modification. 130 amp Tundra alternator - https://forum.ih8mud.com/threads/130-amp-tundra-alternator.196712/
A new plug and pigtails for an 80 series alternator should not be that difficult to wire in to the 60 series harness.
Interesting. I'm also considering other alternators, but then you'd be changing the lower bracket that holds the pivot point, which gets into how the AC compressor is attached. A real can of worms.
Alright, these brackets are live here.
4.7mm thick steel (0.187”), textured black powder coat, one bolt installation.
Are there other alternator upgrades? Sure. Is the FJ80 alternator swap easier than other swaps? With this bracket, I think so. It’s still a DIY project and you’ll still have to figure out the pulley and electrical connector situations, but those have been addressed on this thread. Don’t forget a bigger alternator needs a bigger fuse - my Fusible Link Replacement Kit can take care of that (just let me know if/when you order so I can let you know about the correct size fuse), or you can DIY a solution.
4.7mm thick steel (0.187”), textured black powder coat, one bolt installation.
Are there other alternator upgrades? Sure. Is the FJ80 alternator swap easier than other swaps? With this bracket, I think so. It’s still a DIY project and you’ll still have to figure out the pulley and electrical connector situations, but those have been addressed on this thread. Don’t forget a bigger alternator needs a bigger fuse - my Fusible Link Replacement Kit can take care of that (just let me know if/when you order so I can let you know about the correct size fuse), or you can DIY a solution.
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Adding my experience,
I've done the 80a Denso swap on two 60s and its straight forward, Coolerman plug mod, and go. But, I shorted the B+ power wire on one of the Denso alts and it now drains the battery when left standing (diode tested bad).
Got a replacement unit, Carquest 14461. It looks identical to what others have received, has a short plug adaptor harness and fits right to the Coolerman mod'ed plug. The alt body fits into the 60 mount cradle easily.
As noted, there is now a difference in the fan and pulley stack. The stock 55amp fan and pulley do fit the shaft, but there's not enough room for the nut. (the size and pitch on 14461 is different than the Denso unit, as well.) (It’s also no go w the larger fan and stock 55amp pulley and nut)
The stack of the shaft spacer, fan, pulley and nut have to be figured out to get everything lined up for the 60 application. I think it could all work out with a thinner spacer on the back and thinner nut, but haven't sourced those for now. (The thin spacer below is from the Denso but that didn't solve the issue.)
In the mean time, I'm going to send my Denso unit for repair and swap in the fresh Cruisertrash bracket, but will watch if folks come up with answers for these remain units. They seem to be the most widely available option for the 60s,
(Or, maybe the simplest answer is to hack the double row pulley into a single pulley, if it all lines up w the other pulleys)
I've done the 80a Denso swap on two 60s and its straight forward, Coolerman plug mod, and go. But, I shorted the B+ power wire on one of the Denso alts and it now drains the battery when left standing (diode tested bad).
Got a replacement unit, Carquest 14461. It looks identical to what others have received, has a short plug adaptor harness and fits right to the Coolerman mod'ed plug. The alt body fits into the 60 mount cradle easily.
As noted, there is now a difference in the fan and pulley stack. The stock 55amp fan and pulley do fit the shaft, but there's not enough room for the nut. (the size and pitch on 14461 is different than the Denso unit, as well.) (It’s also no go w the larger fan and stock 55amp pulley and nut)
The stack of the shaft spacer, fan, pulley and nut have to be figured out to get everything lined up for the 60 application. I think it could all work out with a thinner spacer on the back and thinner nut, but haven't sourced those for now. (The thin spacer below is from the Denso but that didn't solve the issue.)
In the mean time, I'm going to send my Denso unit for repair and swap in the fresh Cruisertrash bracket, but will watch if folks come up with answers for these remain units. They seem to be the most widely available option for the 60s,
(Or, maybe the simplest answer is to hack the double row pulley into a single pulley, if it all lines up w the other pulleys)
I ran into the same problem trying to use the 2F alternator pulley - not enough threads for the nut to safely grab onto. The pulley does fit the shaft of the 80 alternator, so maybe playing with spacers is the ticket. I got lucky and found a pulley that works for me at my local mom-and-pop alternator rebuild shop. I’m also running the Saginaw power steering pump and that pulley uses a thinner belt - the alternator pulley I got works for that too.
Do we know the shaft diameter and length on these Rock Auto 80 alternators? I would take mine off the truck and measure today, but I’m halfway through a knuckle job and gotta stay focused on that.
Both spindle shafts measured 17mm.
I took an approximate measurement of the length from the vertical mounting face of the alt body to the end of the spindle length. It’s hard to tell from the pic, but the reman unit is 5 mm shorter in the alt body-to-spindle end length, ~49mm vs ~45mm.
*The width of the bottom mounting lug on both alternators was within 0.5 mm, so that seems to not differ between the units.
So, with the reman unit you lose 5mm in spindle length, and add the wider bushing/spacer behind the fan, and that leaves you without enough clearance for the thicker stock 60 pulley
I think the larger fan and the 55amp fan are roughly the same thickness, though they would require different bushings to clearance the alt body in the stack of parts.
I took an approximate measurement of the length from the vertical mounting face of the alt body to the end of the spindle length. It’s hard to tell from the pic, but the reman unit is 5 mm shorter in the alt body-to-spindle end length, ~49mm vs ~45mm.
*The width of the bottom mounting lug on both alternators was within 0.5 mm, so that seems to not differ between the units.
So, with the reman unit you lose 5mm in spindle length, and add the wider bushing/spacer behind the fan, and that leaves you without enough clearance for the thicker stock 60 pulley
I think the larger fan and the 55amp fan are roughly the same thickness, though they would require different bushings to clearance the alt body in the stack of parts.Update: I located: (i) 17mm x 25.5mm x 1mm shims/spacers; and (ii) a M16 x 1.5 nut that is 8mm thick.
Using the 60 series - 55amp fan and pulley: I used a total of 7 - 1mm spacers behind the fan. The fan just clears the body and the belt pulley lines up well with the crank pulley. I still may add one more spacer to give the fan just a bit more clearance from the alt body.
It all works now and I'm seeing >14v at the battery at idle in the garage...will report back after some miles down the road. I left the larger tension bracket off until I get a larger belt.
I would prefer a single spacer behind the fan instead of the stack, so I'll sort that out when I nail down the final depth/thickness... There's probably room for 1-2mm more, if need, until the M16 nut would not clear the end of the shaft. (Also, the spacer that comes w the alternator is 12mm thick, so with the right tools, one could cut/sand that down to the desired height and be all set...)
Fingers crossed this holds up, feel free to point out anything that looks/seems wrong or less than optimal...
Using the 60 series - 55amp fan and pulley: I used a total of 7 - 1mm spacers behind the fan. The fan just clears the body and the belt pulley lines up well with the crank pulley. I still may add one more spacer to give the fan just a bit more clearance from the alt body.
It all works now and I'm seeing >14v at the battery at idle in the garage...will report back after some miles down the road. I left the larger tension bracket off until I get a larger belt.
I would prefer a single spacer behind the fan instead of the stack, so I'll sort that out when I nail down the final depth/thickness... There's probably room for 1-2mm more, if need, until the M16 nut would not clear the end of the shaft. (Also, the spacer that comes w the alternator is 12mm thick, so with the right tools, one could cut/sand that down to the desired height and be all set...)
Fingers crossed this holds up, feel free to point out anything that looks/seems wrong or less than optimal...
So that’s the 2F pulley on there, with the spacers and skinny nut making it happen? Excellent work.
This would be extremely helpful to folks buying my extend-o bracket.
Looks like I'll help contribute to keeping this long-living thread alive even longer.
Which 80A alternator is the one that works the best (from RockAuto)? From what I'm reading, it looks like the Pure Energy 14461 is the correct one?
Besides the extended bracket and fusible link from @CruiserTrash, and the connector from @Coolerman, it looks like I need to get some shim washers and a smaller nut? Is that all?
Which 80A alternator is the one that works the best (from RockAuto)? From what I'm reading, it looks like the Pure Energy 14461 is the correct one?
Besides the extended bracket and fusible link from @CruiserTrash, and the connector from @Coolerman, it looks like I need to get some shim washers and a smaller nut? Is that all?
I ordered the Pure Energy one, but received a 1FZ alternator in the correctly-labeled box. I'm not sure if it was a mistake or what. I ended up getting the Terra Power.
The pulley is the other thing that needs solved, but like you said spacers and a thin nut might be the way there, as seen above from @jmccandless. I'm currently running a pulley that works that I sourced from a dusty box at the local mom-and-pop alternator repair shop, but I ordered some spacers and thin nuts to test using my 2F alternator pulley. I've been out of town and haven't had the chance to do so yet. I'd like to eventually package as much of this as I can into a kit.
Last note: seems like some of the new alternators come with a generic plug and an adapter pigtail that takes you from generic plug to 80 Series plug. The Coolerman adapter pigtail can connect from that to the 60 Series plug. Or repin the connectors so you're only using one adapter pigtail instead of two.