Alternator Plug

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Racer65

Racer65

10 Year
Joined
Jan 28, 2012
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Location
Palo Alto, CA
Replacing the original alternator on my truck (Feb 1980 build). OEM unit is shown on the right below. It's an externally regulated alternator, part # 27020-61013. According to ToyotaPartsZone, this unit has now been superseded by 27020-61100-84, which is only available as a rebuilt unit by Bosch.

I ordered the Bosch unit from PartsGeek. Unfortunately the connector has different spacing. My questions are:
1. Do all of the new alternators have a different plug, or is there one out there that's plug and play?
2. What are some alternate solutions? Is there an adapter available?

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The Bosch box says AL209X. I have some doubts it's the right replacement part. External dimensions match the original. The differences are with the plug and the pulley. I can deal with the pulley, but I can't work with the wrong plug.

However, I looked up one on eBay, and it has the same style plug.
 
I PM'ed him. Will see what he says. I'm guessing what I need is Part# FLF3P6.3B on his page.

To be honest I'm surprised that even the OEM alternator on my truck is unobtanium, and the substitute isn't plug and play. I remember doing this job 15 years ago on my first Cruiser. I simply went down to a local shop to get the Denso part, and 30 minutes later I was off and running.

I'm really glad Coolerman compiled all this electrical stuff that so many of us are going to need!
 
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I found the answer on Coolerman's site! I missed it initially because all of the sub-pages have the same URL :bang:

It's under "Misc Electrical Parts", where he shows different types of connectors for different alternators. Definitely good stuff.
 
Racer, I got your email. As my web site states: I work full time. I travel, A LOT. I have put in 12 hours before I can even start Cruiser related stuff. The part you seek is currently out of stock, but is on order from Japan and is expected early next week. If this is an emergency I can pull that part off a new harness I have and get it to you. The other items you seek I have in stock. Let me know...
 
New update. I obtained the rebuilt alternator sold by Toyota, part # 27020-61100-84. It has the identical green plug and pulley as the original. Total plug and play. I'm going with this one!
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In summary, for those with a '77 to '80 FJ40 with an OEM Nippondenso alternator (part # 27020-61013) there are two options:

Option 1: Get Toyota part # 27020-61100-84 as plug-and-play replacement. Note that this is a rebuilt alternator sold by Toyota.
Option 2: Get Bosch part # AL209X (This is also a rebuilt alternator) and make 2 modifications:
1) Buy plug #FLF3P6.3B from Coolerman. Take the 3 terminals out of the old plug, and insert into the new plug. Keep in mind the terminals need to be switched from the "FEN" green plug configuration to the "EFN" configuration on the new plug.
2) Swap the pulley from your old alternator onto the Bosch unit.

Cost considerations: The Toyota alternator costs $126 including a $10 core charge. The Bosch alternator can be found for as low as $50.
However, converting the Bosch unit requires some tools:
1) Taking the nuts off the pulley requires an air impact wrench
2) Taking off the pulley may require a pulley remover
3) Taking the terminals out of the plug requires a terminal removal tool

Your choice!
 
Random place to put this maybe...

This is the original alternator from a '78 that was parted out around 1980 or '81. It's been in storage ever since. I'm swapping it into my '76 today.

The one that's going bad has a bearing problem. It still charges fine. I have no idea about it's origin. It came with the truck. It doesn't have this OEM sticker on it though.


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I have a '78 250 K miles on original denso alternator. What are best options for a higher output alternator - mine really pulls down using winch even with dual batteries.
 
My other rig has one of these. It Can put out the rated power all day long.

Ford / Mitsubishi F5UU10300CA, A8TU0091 215 Amp Alternator | eBay
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Installed on the PS it could even help reduce cruiser lean. It comes with an 8 groove belt so some things would need to be done to make it work. It changes my 4 batteries nicely. :D
 
ran into that years ago so i saved all my newer style plugs for that purpose
 
I had my original alternator rebuilt and rewound to higher output for about the cost of the Toyota unit. If my memory is correct - I'm at 105 amps now. A local small business did the job.
 
Norseman66 said:
I have a '78 250 K miles on original denso alternator. What are best options for a higher output alternator - mine really pulls down using winch even with dual batteries.
Click to expand...

Mean Green is about 160 amps I believe. About 400.00
Quality Power is 140 amps.....250.00ish
 
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