Weak alternator voltage.. Fixed, under $30 (1 Viewer)

[caladin]

My alternator was.
Outputting 12.4-13v


I was planning to upgrade to the fj62/80air cooled alt. In prep for that, I ran a 2awg 12" lead from + on the passenger side battery to the charge terminal on the alternator, then one from a good body ground to negative(battery tray diagonal bolt to fender). Both wires are in parallel to the stock harness.

I am running about 14.2 volts now, with my old tired alternator.

These leads just barely fit, if you route them properly.

In case someone wants it below are the wires I ordered. They fit with very little slack.

Battery Cable 2AWG 12 Inch... Amazon.com - https://www.amazon.com/dp/B0B3TFTXVK?ref=ppx_pop_mob_ap_share

Had a spare 2awg black cable from old project, and added a ground to 2nd battery.

Next to put ground from - on starter to bolt on the fender, doing this added years of trouble-free service, from an already unreliable starter on my FJ40.



Side Question, I used my last spare fusible link fixing my dad's fj60 at the ranch.

Does anyone know where to still get oem fusible links?

Thanks

 

[caladin]

Adding a link to a thread on how to hack up a temporary fusible link w/ fuses, and Fl wire size info to fix the old fusible link, for later reference.
FJ60 Burnt Fusible Link Fuse replacement / Rewire - https://forum.ih8mud.com/threads/fj60-burnt-fusible-link-fuse-replacement-rewire.1312417/

 

[Hokie LX]

Using 0/2 cable for grounds on my 60 and replacing my fritzy fusible link that had burn marks in it (pics in my thread) yielded me 14.1+V at idle now which I'm thrilled with from my 55A alternator. New grounds are a good idea for any of these trucks at this age.

 

[Seth S]

If you run the marine cables they will be less prone to corrosion.

 

[CruiserTrash]

@caladin Big cables make a huge difference, don't they! People go replacing the alternator right away, when most probably don't need to. Open up those cable sizes and let the alternator breath! I've upsized all my grounds, as well as the positive cables for the starter and the alternator - most of those came from @Fourrunner , he makes a really good kit. I haven't done it yet, but I'd also like to run a larger cable from the battery/alt to the fuse panel in the cabin. Toyota used 12awg for that, and I really think it could benefit from being larger (and having less resistance).

FYI I make a plug & play fusible link replacement system for FJ60s. It takes zero electrical knowledge, about 15 minutes of time to install with the custom bracket, and most people see about 0.5-1V increase at idle. There are two versions: basic and an upgraded alternator charge cable. All parts used to build these are super high quality, zero Amazon junk. I even source Yazaki wire from Japan, the same stuff Toyota used when they made these trucks. You can check it out here.

 

[84Landie]

For those of you that were seeing weak voltage at idle, was that under load or not? Mine puts out 13-14V at idle, but that drops to under 12.5V with AC running. Seems worse when warm.

I’m planning to check grounds and may add cables since this is cheap and easy. Seems like alternator is next step

 

[caladin]

For those of you that were seeing weak voltage at idle, was that under load or not? Mine puts out 13-14V at idle, but that drops to under 12.5V with AC running. Seems worse when warm.

I’m planning to check grounds and may add cables since this is cheap and easy. Seems like alternator is next step

Was weakest at Idle, 12.4v ish, would popup to 13 barely after driving a bit, not just at holding 2200rpn for a few seconds like folks said. Didn't always hold there.

I have a toyota rebuilt volt controller too, that was my next step after big wires, and before new alternator. They were like $10 from Toyota.
Part # for Toyota rebuilt voltage regulator is 27700-38100-84 (looks like I got a steal, best price I see now is $38 each for the Voltage Regulator, glad I bought 2, wish I'd bought all 3 in stock )

 

[84Landie]

I just went ahead and ordered a regulator from Toyota. Thanks!

 

[ToyotaMatt]

If you run the marine cables they will be less prone to corrosion.

i hand assemble all my Battery Cables and Cable Bond No. 1 out of ANCHOR Marine Grade 2 AWG its a SOLID SAE 1+ next step up in side spec. from the FJ62 set up ...

the rest of all parts are OEM TOYOTA General Service Japan. spec. ones ....

Tinned-Fine strands ANCHOR brand is the US Military Go-To Product , also out on the high seas with the USCG & Navy ...




my B+ Positive has the added my rugged SNOW-VERSION GRADE spec. applied heavy duty tough as Nails ,with the Super heavy duty style of Corrugated Loom end to end
.

.




NEG- GROUND i color key in YELLOW with ANCHOR adhesive lined shrink in lock step with OEM TOYOTA

,

 

[ToyotaMatt]

CABLE BOND No. 1 is a absolute essential when running a OEM TOYOTA Gear Reduction Starter Motor !
.

 

[caladin]

link to 2awg 12" marine grade cables on Amazon.

12" fit without much slack, to the passenger side battery, which is what I wanted. I didn't upgrade to marine grade, just put the link here for those who follow.

Amazon.com