Gregturley

Load tested the alt with stock pulley today. About 110 amps at idle. Didn't get to test at 2000 rpm like i wanted so im waiting to change the pulley until i can. The cut down nut adds right at 2 full threads on the washer side of the nut. It took 3 turns of the stock nut to get the nut flush with the end of a bolt. Vic nut took 5 turns. They are both roughly the same thickness. Definitely has more thread engagement than stock nut and the washer face is just a hair larger diameter.

Got my router back today and started on the wheels.

@Bullet i have 2 more sitting on my box at work. Send me your address. I'll cut them down and mail them out to you. I have an almost endless supply of them on the vics they are a 1 time use because of the nylon insert.

@kzimmer i can't stand newer fords other than the Vic. I work on them every day. Our fleet is about 90% ford mostly vics, taurus, focus and explorer. Besides the vic complete garbage. We have some Dodge chargers, challengers, and mini vans. Since I'm the lone Mopar guy i do get every one that comes in. Getting 13 new chargers soon so we'll see how they are. Told they were 5.7 all wheel drive.

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

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.

@dripley I've seen weights all over the place. 2700-3200 range. I think enough people are using them without issue that I'll be fine. I'm building this truck up for retirement and thats 3 years off. Thats when I'll be hauling a 5th wheel if we go that way. I'm sure between now and then i can find something better if need be. Loaned my router to a guy at work so when i get that back I'll open up the center hole and test fit. Might blast and powder coat after that.

@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.

@dripley when i looked before i thought i saw about 3200. I'll check it out some more and follow up.

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.

I have been looking for some cheap 17" wheels and ran across 5 H2 Hummer wheels for $125. The guy had a white rust free rear door for $100 so i got it too. Found a HX35 with 50k on it for $200 shipped. I have to quit spending money on this thing.

Dont waste your money on the J-hook. Go to the hardware store and get some extension springs. 2 springs about 8-10 inches long. Hook 1 spring where actuator connects to turbo. 2nd spring hooks to other end of 1st spring. Then hook 2nd spring onto alternator bracket. Springs need to be relatively stiff. This holds wastegate closed longer to build more boost. Tune max boost by cutting 2nd spring. Costs about $4.00, takes 10 minutes. I have mine done this way and set at 28psi max with a hy35

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.

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.

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.

@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.

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.

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

@kzimmer you using any loctite?

@Blueox01 check your crank pulley to make sure its not coming apart. Real common to find when belts start getting torn up.

I will measure everything with a good dial caliper. The 2 stock Dodge pulleys fit slightly different. 8 groove fit tighter on the shaft of both alternators. 1mm=0.03937 inch. 1/25.4 inch. Like you said not much.

@Bullet you'll never see 1mm misalignment. People get press on pulleys off by that much or more all the time with no problem. Watching my belt track it looks like it rides right where it always has. Interested to see what @kzimmer says about his.

Checked a/c voltage at lunch. Idle with nothing on .015-.029. High idle with grid heaters on .025-.032. I rechecked my notes from last test and i was wrong about my max. I had .02 max at idle with nothing on. No notes on high idle or with grids. Have not been able to load test it yet, might be tomorrow.

Got the pulley ordered this am should be here Friday. $14 after tax from eBay.

@Doubletrouble thats fine just let me know. Good luck with the job.