Dredging up this thread as I am undergoing the same upgrade, but running into some issues. I see the OP hasn’t been on since 2020, so maybe others can chime in with advice.
I have installed the same 140amp alternator on my ‘87 FJ60. I have the upgraded wire running to the battery. I disconnected the green plug, but left the two white wires also attached to the alternator as they feed the starter and harness (I believe).
When I turn on the car, the alternator sounds a little whiny, and after 10 to 20 seconds, it starts to bog engine more (presumably output is increasing, backed up by voltage meter). Then it just runs rough and sounds like it is struggling to idle.
I turned the car off (fearing I might be doing damage), and can feel the pulley and fan on the alternator are already too hot to touch.
I am thinking that either Quality Power shipped me a unit with a pulley that is too large (meaning width, as the belt sits deep within the pulley) which is causing the belt to slip, creating friction and thus heat…or incorporating the original fusible link wiring is somehow causing issues.
Looking at Quality Powers Website for their pulleys:
I see they have two options for 5/8” wide pulleys…I straight 5/8” and a 5/8” to 3/4” option. It appears I received the latter option which may account for how deep the belt sits, however they make it seem like you can run either size in this pulley? So maybe not the issue? I will say that after tensioning the belt, I could, under moderate force, rotate the alternator pulley! This seems like a sign something is off.
Anyway, if all of you super helpful alternator experts could lend me some advice, I would sure appreciate it.
Shahn
I have installed the same 140amp alternator on my ‘87 FJ60. I have the upgraded wire running to the battery. I disconnected the green plug, but left the two white wires also attached to the alternator as they feed the starter and harness (I believe).
When I turn on the car, the alternator sounds a little whiny, and after 10 to 20 seconds, it starts to bog engine more (presumably output is increasing, backed up by voltage meter). Then it just runs rough and sounds like it is struggling to idle.
I turned the car off (fearing I might be doing damage), and can feel the pulley and fan on the alternator are already too hot to touch.
I am thinking that either Quality Power shipped me a unit with a pulley that is too large (meaning width, as the belt sits deep within the pulley) which is causing the belt to slip, creating friction and thus heat…or incorporating the original fusible link wiring is somehow causing issues.
Looking at Quality Powers Website for their pulleys:
wide groove pulleys,alternators,starters, batterie
Having trouble finding a wide groove pulley for your alternator to use with the 1/2, 5/8 and 3/4 belts found on older vehicles? We have the wide groove pulley you need. You can also use them to replace the large diameter pulley on an OEM generator or when adapting an alternator to replace an...
www.qualitypowerauto.com
Anyway, if all of you super helpful alternator experts could lend me some advice, I would sure appreciate it.
Shahn
