In my search for a better alternator i came across a post by ilya5903 on Cumminsforum.com about using a 2001-03 5.9 Durango 160 amp alternator. Today i hit Pull-a-Part and lucked out. They had 2 Durangos and one was a clean 02 5.9 with the factory alternator. $22 + $7 core. Had it tested on the way home and it works. Swapped the pulley and 15 minutes later its on. Definitely puts out more at idle than the stock 136 amp as i can now have all 3 air compressors, a/c, high blower, headlights and stereo on with truck at 800rpm in drive and had 13.9 volts. 14.2 at idle in drive with everything off.

 Factory pn 56029915AA.

https://www.cumminsforum.com/forum/98-5-02-powertrain/2422026-denso-hairpin-160a-alternator-upgrade.html#/topics/2422026?page=1

6 hours ago, Gregturley said:

@kzimmer you using any loctite?

You know, I was thinking about that today. I think I remember throwing some blue loctite on there.

I was going to put red on it. Impact gun will take it off later if needed.

I try to avoid red. Me and red don't get along. Lol

Years ago i used red loctite on my buddy's spare tire wing nut. He was a cop that rode in an area with a lot of construction. He didn't see the humor in it when he had a flat in the rain and couldn't get his spare out. It was payback for him pulling me over daily for months.

Rockauto and several other parts houses list the part number for 02 to 03 rams also, I'm sure I have one off of 02 5.9 v8 but I think it's 136amp, looks like there was117/136/160 amp alternators used at that time... bet the one I have is not 160

@wil440 i saw that listed in the article but have not confirmed it myself. Be good if correct. I'll do a numerical listing on Napa computer in a few and see what i come up with.

Update: NAPA listing is for 01-03 Durango 5.9l V-8. No pick-up trucks. That is using the Mopar factory number.

Edited January 29, 20205 yr by Gregturley
Info

16 minutes ago, Gregturley said:

@wil440 i saw that listed in the article but have not confirmed it myself. Be good if correct. I'll do a numerical listing on Napa computer in a few and see what i come up with.

It took a while to check on RockA as they don't seem to have the years and models parts fit anymore or at least I couldn't find it, they used to have a cross ref within the info

I had my NAPA guy cross the factory alternator number to a NAPA number. Then did a check of all vehicles that use the NAPA number. Durango is all that it shows. I am not saying this info is 100%, just that I cannot easily verify a use on a pickup.

 Mopar may have used a 160 amp alt on some trucks, and it may work for our trucks, but they could have made some minor change like where the charging stud is located. A change like that will get a different PN.

Here's the link to one

https://www.thewrenchmonkey.ca/products/auto-parts/tyc/213915/

Anyone know anything about a factory 180 amp alternator that may have been used on a Dodge ambulance package with the Cummins engine? I've heard rumors of it but have not been able to find any info or part numbers to back it up.

7 minutes ago, Gregturley said:

Anyone know anything about a factory 180 amp alternator that may have been used on a Dodge ambulance package with the Cummins engine? I've heard rumors of it but have not been able to find any info or part numbers to back it up.

Allpar have an ambulance page with a cummins ram and also mention a v10 3500

I know they made them, I've seen pics but havent been able to find anything out about the charging system. 

Our meat trucks are fords and they used twin alts because of the electrical demand from lights and emt equipment. We've never had any Mopars.

Never had a chance to load test the alternator this past week. Bad things going on at work. Hopefully things calm down so I can do it this coming week. Pulley showed up today and i did a test fit on my 136 amp. Definitely not a lot of thread engagement. Think ill try to find a different nut to try. 

Yeah I know. It was right borderline for me to decide whether or not I should do something about it. I decided not to. Let me know what you figure out.

Can't a guy drill a 1/4" deep through the hole with a bigger drill bit so the nut sinks a little dipper in to a pulley. 

Yeah I think it could be machined down a little.

@Dieselfuture i was going to try that but i don't think so. The back of the pulley is tapered pretty good. Don't think there'd be enough material there after machining. I'll get some measurements tomorrow and post them for you.

1 minute ago, Gregturley said:

Don't think there'd be enough material there after machining

I see, make sense after seeing the picture. I was just thinking out loud. 

I thought the same thing until i got it in my hand. I'm thinking jam nut, thin washer and loctite after looking at it. Think it's a m14x2.0 thread but have to double check all that. I was lazy today and didn't get enough done.

Alternator nut thread is m14x1.50. 

There is NOT enough material to cut down the pulley for more thread engagement. The pulley is just under 1/8" (.121") thick in the area that would need cut down. 

My solution is a modified Crown Vic ball joint nut. I cut off the captured washer and the top of the nut that held the nylock insert. I gained 2 complete turns of thread engagement. 

Vic nut on left, factory alternator nut on right

Before and after of Crown Vic nut