Alternator help - fj60 (1 Viewer)

[mccracken]

4 years ago I bypassed my stock charging system with a high output single wire alternator. It was great and worked. That alternator died.

I went back to stock this past week but I’m barely getting 12.5v measured at the terminals while charging.

I noticed the single wire coming off my alt had a “fusible link” label on it which wasn’t stock. I filled it back to the actual stock three wire fusible link and found the solder mess below.

1. I have a couple theories as to why BUT my real problem is I need to drive this rig this weekend. Anyone have a photo of a stock 60 charging setup so I can confirm I need this single wire?

2. Anyone have one of these male green connectors lying around that I could re wire my setup with? Or is it plausible I could rewire the one I have? This thing looks like a mess but idk maybe it’s not that bad after cutting off the bad and cleaning it up??


Open to all suggestions. My weekend warrior parent brain is spread to thin to figure how to solve this fast but correct. Hah

 

[mccracken]

I’m to confused by wiring diagrams to tell if I need this direct single wire on a stock charging system setup. I’m thinking at some point there was a temporary bypass of the normal three wire fusible link which is why there is single wire fusible link spliced into the stock harness.

 

[AirheadNut]

Looks like the melted/soldered wire is actually downstream of the fusible links, which is good. Not sure why that black wire is tied in but it doesn't look stock at all. I wonder if there was a short or a poor connection somewhere and a previous owner tried to bypass it?

Do you have a photo of the pins inside that green plug? I might have some new terminals that could be crimped on to a good section of the wire and reinstalled in the plug housing.

 

[1989FJ]

@mccracken CruiserTrash makes a kit to replace the fusible link, might be easier than trying to rework the existing, pricey though.

Edit- Now I see that there’s still wires that would need fixing past just the fusible link, so the kit probably wouldn’t be a plug and play solution.

Cruiser Trash Parts

vintage Land Cruiser parts and paraphernalia

cruisertrashparts.com

 

[mccracken]

Looks like the melted/soldered wire is actually downstream of the fusible links, which is good. Not sure why that black wire is tied in but it doesn't look stock at all. I wonder if there was a short or a poor connection somewhere and a previous owner tried to bypass it?

Do you have a photo of the pins inside that green plug? I might have some new terminals that could be crimped on to a good section of the wire and reinstalled in the plug housing.

I’m struggling on that front because I have never removed terminals from plugs. Don’t want to damage it because I’m a fool hah. I’m working on figuring this out via YouTube U so TBD.

I used BAT to view some stock engine bays. Seems like most 60s have a single wire separate from our combo wire. I can’t figure out what it’s for or where it goes but mine doesn’t seem to serve the same purpose given the soldering? I checked the ohms through the red wire on the three wire fusible link and that seems to be OK and not an issue.

 

[mccracken]

@mccracken CruiserTrash makes a kit to replace the fusible link, might be easier than trying to rework the existing, pricey though.

Edit- Now I see that there’s still wires that would need fixing past just the fusible link, so the kit probably wouldn’t be a plug and play solution.

Cruiser Trash Parts

vintage Land Cruiser parts and paraphernalia

cruisertrashparts.com

I think if I was gonna throw money at this id probably just go back to my high output setup since I know it works just fine. I have seen this kit though but I think your right that it won’t out right solve what I’m working with.

 

[mccracken]

Sit rep: based on photos of other engine bays I went looking for the missing cables. Cut back the loom and found em! Not super pretty in there but makes more sense now. One wire was super short so I spliced in a fresh section and connected it to the alternator. The second is the one with the jacked up fusible link soldered in. Added a new connector to the end of the white wire and then cut off the black one causing confusion. Tried to cover any exposed wire with shrink wrap and electrical tape.

Showing 13.5v now which I believe falls on the low end of acceptable! Probably more to be gained by actually replacing the full wire but that solder mess was so dang close to the connector and I’m not prepared to pull the connector apart.

 

[AirheadNut]

Awesome troubleshooting! Glad you found the issue. If you want a hand rewiring that plug I could definitely help with that, I’ve got the crimper to do that style of pin and have wired several connectors like that.

 

[mccracken]

Awesome troubleshooting! Glad you found the issue. If you want a hand rewiring that plug I could definitely help with that, I’ve got the crimper to do that style of pin and have wired several connectors like that.

That would be rad. It stresses me out knowing it’s probably a matter of time before there is more trouble. Gonna be at the bbq?

 

[AirheadNut]

That would be rad. It stresses me out knowing it’s probably a matter of time before there is more trouble. Gonna be at the bbq?

No, I'm going to be out of town the next couple of weekends, but can swing by any weekday after work and lend a hand.