Hi all, I have a 1991 HDJ81 (JDM) with the 1-HDT that I will be upgrading the alternator on. As far as I know, I have the original, stock DENSO 60 Amp 12v alternator (27060-17020). I am pretty sure of this because on ToyoDIY, for my VIN, I can either have a 60 Amp or a 100 Amp alternator from the factory, but since I do NOT have the "cold weather package", I believe my factory alternator is the 60 Amp version. I did have the factory AISIN winch, if that makes a difference.
Anyway, I will be upgrading to the Terrain Tamer 120 Amp 12v alternator (27060-17250TT) and I wanted to know two things:
1) Do I need to increase the wire size that runs from the alternator to the Left Hand battery positive terminal?
2) What about any fusible links for this alternator-to-battery wire? I did not see any fusible links on the wire that runs from the alternator to the left hand battery positive terminal.
To be clear, I visually traced the wire that runs from the stock alternator output and it goes over the radiator and goes directly to the left hand battery positive terminal (not the right hand battery like I would have thought...the right hand battery is so much closer to the alternator, doh!). My concern in this scenario is that if I have a stock 60 Amp alternator and I go and put in a new 120 Amp alternator, that the stock wire size will be insufficient. As an example, the Radd-Cruisers website shows for their 110 amp high output alternator that for a wire run of less than 5 feet that a 4ga fine stranded copper wire should be used. For runs over 5 feet that a 2ga wire should be used. Also, that the wiring should be protected with a fusible link as well.
Any other advice on this?
Also, I do know about the need for the 3-pin adapter to go from the round to oval connection since mine is a 1991 HDJ81 (the new Terrain Tamer only has a round 3 pin connection and the early HDJ81's had an oval 3-pin connector). Also, I am aware of the need for the longer alternator adjusting bar/tension bracket (16381-17020) to be able to fit the larger 120 Amp alternator.
Thanks!
Anyway, I will be upgrading to the Terrain Tamer 120 Amp 12v alternator (27060-17250TT) and I wanted to know two things:
1) Do I need to increase the wire size that runs from the alternator to the Left Hand battery positive terminal?
2) What about any fusible links for this alternator-to-battery wire? I did not see any fusible links on the wire that runs from the alternator to the left hand battery positive terminal.
To be clear, I visually traced the wire that runs from the stock alternator output and it goes over the radiator and goes directly to the left hand battery positive terminal (not the right hand battery like I would have thought...the right hand battery is so much closer to the alternator, doh!). My concern in this scenario is that if I have a stock 60 Amp alternator and I go and put in a new 120 Amp alternator, that the stock wire size will be insufficient. As an example, the Radd-Cruisers website shows for their 110 amp high output alternator that for a wire run of less than 5 feet that a 4ga fine stranded copper wire should be used. For runs over 5 feet that a 2ga wire should be used. Also, that the wiring should be protected with a fusible link as well.
Any other advice on this?
Also, I do know about the need for the 3-pin adapter to go from the round to oval connection since mine is a 1991 HDJ81 (the new Terrain Tamer only has a round 3 pin connection and the early HDJ81's had an oval 3-pin connector). Also, I am aware of the need for the longer alternator adjusting bar/tension bracket (16381-17020) to be able to fit the larger 120 Amp alternator.
Thanks!