Alternator altering

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OK great! As soon as I see it works correctly I will post the connectors for sale on the web site.
Appreciate the feedback Jim. If you ever need weird connectors/adapters let me know. I can build a lot of strange stuff...
 
Here's where we started, a temporary 'proof of concept' adapter harness from the FJ60 to the FJ62 alternator:

DSC07174.jpg

The concept worked perfectly. Since there is no reason to go back to the FJ60 alt, the 60 connector will be cut off and replaced with the 3FE connector. The 3FE alternator plug has 3 terminals vs the FJ60 2 terminals. They are IG at the top (+12V IGnition power), S at the 3o'clock (Senses chassis voltage, tries to keep it at ~14V), and L at the bottom (turns on charge Light if alt is not charging).

DSC08885.JPG

Electrically, the only difference is the additional S terminal at the top. It can simply be connected to the +B post with a large ring terminal, as the factory does in the FJ62 harness.

The black FJ60 IG wire should be connected the center IG terminal.

The white FJ60 L wire is connected to the bottom L termianl

Wires ready to be crimped together.

DSC09209.JPG

The rubber boot on the smaller 2F connector is the same OD as the new connector, so it gets taped to the end of the connector, it won't actually slide over the connector. It's better than nothing.

DSC09210.JPG

After crimping & taping, the 3FE connector from Coolerman fits perfect in the back of the alternator.

DSC09213.JPG
 
Great news! Jim in the pic showing the two wires from the FJ62, are they Black/Yellow and Yellow/White? Black/Yellow to IG and S and Yellow/White to L? 18 or 16ga? Looks like 18ga...

Working on two versions of this "3FE Connector Kit". Kit #1 for the DIY person: Comes with the 3FE connector, three terminals (one terminal is 12ga to allow two wires to fit in it) and a Red rubber boot to fit over the 3FE connector end.

The other "kit" would consist of a pre-terminated connector with 1 foot long, correct colored wires (can order longer wires), the red connector boot and two butt connectors, (or you can solder it on), for those that don't have the tool to properly crimp the 3FE connector terminals.

I will build a couple of these over the next couple of days to get an idea for pricing, then put them up on the web site.

If you would like to install some other alternator with a weird ass plug, take a picture of the plug AND the socket on the alternator, supply the manufacture name and if possible the vehicle it originally came from ,and post all that in this thread. I can probably find the connector for it.
 
Mark, I don't like the way I did this connector swap. It could be done much easier, assuming the terminals are the same inside the FJ60 & 3FE connector shell.

Easy install:
  1. Insert Coolerman supplied Sense wire into cavity 1.
  2. using terminal release tool, remove BY & W colored wires from FJ60 connector.
  3. slide 3FE boot up the two wires
  4. insert BY wire into cavity 2 (IG connection)
  5. Insert W wire into cavity 3 (L connection)
  6. plug connector into alternator
  7. attach ring terminal end of Sense wire to B+ stud.
Coolerman's EZ 3FE swap kit would consist of:
  1. 3FE connector shell.
  2. Sense wire, an 8" long 16ga wire with preterminated 1/4" ring terminal and female spade ends.
  3. rubber boot to fit connector.

This could also work on FJ40 2F with external regulators. They simply delete the part about connecting the W colored wire to the L terminal. It would require crimping together the BY & WG colored wires at the regulator, then picking the WG terminal out of the original alt connector and plugging it into cavity 2 (IG connection).
 
Ok last night I made up one of the connectors and discovered that the boots I have will not fit the 3FE connector. I don't see how ANY boot could be made to fit due to the snap locking connector. It appears that there should be a rubber plug that would fit INSIDE the back of the connector and the wires would come out that. I contacted the source this AM and was told that connector does not come with a boot. I would like to see the Toyota boot. Anyone got a pic of one? You can see in the pic why a "normal" boot will not slide onto the back of the connector.

Jim, what I did for the FJ62 pre-terminated version was to connect the Ig and S wires onto the IG terminal and bring the IG and L out to be butt connected or soldered to the stock FJ62 wires. That way the Sense terminal is actually reading mid harness voltage which would give a more realistic reading for the alternator to act on. Connecting it to the B+ on the alternator would always have the Sense voltage a bit high resulting in lower alternator output.

Working on the web page today so check it tomorrow for the new item. It will be under Alternator Connectors.

3FE1.jpg
 
Last edited:
Good point about the B+ post & S wire.
That is a better way to do it.

FWIW, the FJ60 white wire is kinda large, prolly 16ga. B/Y wire is skinnier, 18 ga.

If the installer has a terminal release pick, they can remove the L wire from the 60 plug and snap it into the 3FE connector, avoiding one cut&crimp.
 
Mark, will order a couple of the pre-terminated kits, and other stuff, this afternoon (CA time ;)).

Just an FYI -
The big RED copy listing the new product should read: "... 80 amp alternator in place of 55 amp alternator in the FJ60 and in the FJ40*..."

And the OPTIONS should read FJ60 bare kit, etc... , also...

Thanks very much for doing this. :cheers:
 
Mark, another thing to edit slightly. Part #3P786.3 fits EXTERNALLY regulated alternators. There's even a pic of an alt without a regulator.

Handy stuff you're selling. Keep up the good work.
 
I want to buy one of these connectors for my FJ60 but a couple of description errors on coolerman's web page make the choice confusing (12/19/14). Thanks for making this plug. I'd like to get one.
 
Took a couple of weeks of much needed vacation during the holidays. Thanks for the feedback regarding the web site part descriptions. Sorry for the confusion on this. I am a one man business, and web stuff (especially typing) is not my best skill! The descriptions are now fixed!

Output Shaft, send an email to fj40coolerman@gmail.com describing what you want and I will get back to you with a total and payment information.
 
FWIW, those of you who want a DENSO reman 3FE alternator, it looks like they've been discontinued, though there's a small supply still out there, as well as some still available at the dealer.
 
Spike Strip said:
FWIW, those of you who want a DENSO reman 3FE alternator, it looks like they've been discontinued, though there's a small supply still out there, as well as some still available at the dealer.
Click to expand...
And so begins the run on alternators!
 
IGOTMINE!
 
uggg.
I guess the only way to win/lose is to bend over and buy a new Tacoma every 5 years.. Mr. T. has it all figured out.
 
Fits puuuuurrrrrfectly !

Thanks Mark!
IMG_3571.JPG
IMG_3570.JPG
 
About $140. Denso boxed, not Toyota.
 
Output Shaft said:
uggg.
I guess the only way to win/lose is to bend over and buy a new Tacoma every 5 years.. Mr. T. has it all figured out.
Click to expand...
10 years after gm put it down...
 
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