Alternator failed, damage is done, new wire harness

[dubyahard]

Need some help here on some recent damage done.

In July 2024, I was on a family road trip and my original alternator died, est. 210k. It was the day before the 4th and I needed to leave the 5th so I didn't have any timely OEM options. I put an Orielly alternator in and all was well...

Until July 2025. Just before a full year of use, the Oreilly alternator died with no warning. I was in my driveway and was about to go out of town again, so I put the trickle charger on and left it. I finally had time to drop it off at a nearby shop a week ago. With the battery topped off, I drove it three miles and parked it. The next morning they went to move it to the back to get ready to pull it in. The tech had just turned it off and walked in the shop while another tech noticed smoke coming from the lower passenger side. Quick work from the tech (thank you!) extinguished a small fire on the back of the alternator. It maybe lasted 30-45 seconds. I assume the alt ramped up quickly to charge the depleted battery and b/c it's a POS Oreilly one, it overheated.

I'll upload some photos later, but they are replacing the alternator (OEM this time), the fusible link since it popped, and they are recommending replacing the Engine Wire No. 2 harness (Part # 82122-60570). It is scored and the cover is burnt near the alternator. There was no other noticeable damage beyond this.

Now we can't find the part. It shows available, but you can't order it. Dealers say there are none in the country and one says it is made to order with 4-6 week lead time.

Question: is this something I could have custom made? Have folks who've upgraded their Alternators in the past done this? Any ideas for other sources? Partsouq shows not available.

Another question: I trust this shop, but does their assessment seem sound?

Lastly: Has anyone else replaced this themselves? How hard was it?

YELLOW highlighted part

 

[bloc]

With that kind of lead time I’d seriously consider finding someone that is willing to repair the existing harness. Someone very good at their craft. It isn’t that difficult, it’s just that most places don’t want to take the risk of problems down the line. It won’t be cheap, but between the cost of the replacement and the downtime of the vehicle…

Yes the assessment seems plausible. These things aren’t designed to deal with fire, but the back of a parts-store alt causing a small one isn’t unrealistic.

Another thought is to contact Toyota parts departments in different parts of the country. The broader parts network is a little complex but more importantly a given person can claim to be an expert but have no clue what’s going on outside their little bubble. @OGBeno regularly debunks some of these guy’s BS.

 

[dubyahard]

Well, I found one from a wrecked Lexus for not too much $$$ so I'm going to give that a shot. It arrives Friday - way better than 4-6 weeks.

I did talk to the Bell Lexus parts guy who has helped me in the past and he did not think the lead time was feasible.

Pictures of damage

 

[bloc]

That is really minimal damage.. appears it's only the connector for the alternator that is damaged. You got lucky.

Also, try to get as much of the fire extinguisher material off of everything as possible. If it was a typical ABC rated "dry chem" those compounds are usually very corrosive.