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Dual alternator install - successful!

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  #1  
Old 02-04-2004, 11:16 AM
chriseyring chriseyring is offline
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Thumbs up Dual alternator install - successful!

I made some posts last year trying to get input on installing a second alternator - on a 2000 PSD. I got some great feedback and completed a successful installation last night. I worked very hard with my test meter and did a ...... shall we call it custom use set up, rather than placing faith in the PCM. Here are the highlights.

1) New factory (2nd) alternator purchased off eBay for .... $60 from an ambulance conversion company that takes them off new.

2) The factory second alternator bracket is readily available from Ford. F8TZ*10A313*AA. You need to specify the "passenger side". Althought the brackets are the same part number, they are definitely not the same bracket. $130.45

3) You need an additional idler pulley that bolts into the new bracket. F8TZ*8678*FA. $20.48

4) You need three replacement bolts. Two of which will replace existing bolts (shorter ones.) that fit into the a/c mounting bracket. The other one replaces a bolt (shorter one.) that fits into the front of the engine block. It holds down the main groundng cable on the back side, and holds the tranmission cooler and wiring set on the front side. N606068-s100 (x2) and W701844-s309 (x1). The nut on the latter bolt is reusable.

5) You need three alternator bolts. These are the same as the bracket hold down bolts. N606068-s100.

6) I was sold a wiring harness that was designed for the original 110 amp alternator that Ford offers in the dual optional alternator set up. The plug is not the same if you get the standard PSD alternator. These are AMP brand connectors and the plug pins can be released and snapped into the other plug. When I got my alternator from eBay, it had the factory plug and about 3 inches of each wire. You may need the plug. The color coding is not correct either, but you're only dealing with three wires....... deal with it. F81Z*14305*CA $45.97

7) Finally, you'll need a new serpentine belt. Dual alternator option. JK8*1381* $66.18.

Installation took about 3 hours and was made easier by removing the top idler pulley (blocks one of the mounting bolt locations.) and by removing the serpentine belt. (Blocks everything). After carefully studying several different wiring schematics, and noting that they are all different, I made the connections by bolting the main output wire to the fusable link on the passenger side where the other alternator and both batteries already connected. I connected my ignition wire (orange/lt. blue) wire to ignition connection of the #1 alternator.

The exciter control wire (Light green/red) is supposed to connect to the PCM. I have been over the truck 100 times with Ford techs and other thinktanks and I cannot find the connection place. However, during the testing of the second alternator at idle speed and under varying loads, I deceided that a manual control switch was going to be sufficient. I already had an Isspro volt/ammeter set up, and found that use of the second alternator holds that volt meter steady at 14.8 volts....... high beams, a/c, and 16 - 55 watt off road lights.

Although not thinking is an easier way to operate, the manual alternator control will force me to monitor electrical loads. Through testing at different points, I have concluded that the built in voltage regulators on these Motorcraft alternators work very well. There is no bouncing or spiking of voltage, and they seem to load share almost too perfectly. Keep in mind, I am running 2 140 amp alternators. Not the 110 amp units that Ford uses on the factory dual set up.

Always happy to have more input. Pictures will be taken and made available on request. Thanks to those of you who gave input last year. So far I couldn't be happier

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Old 02-04-2004, 06:39 PM
Paso1 Paso1 is offline
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Awesome post thanks for doing the leg work and documentation of the job.
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Old 02-04-2004, 07:02 PM
Builditstrong Builditstrong is offline
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the dual factory setup is (2) @ 130 amp...
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Old 02-04-2004, 09:20 PM
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cangim cangim is online now
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Awesome work, My neigbor setup his truck with the dual As, he uses the second alternator to charge a couple of Deep Cells in the bed, they run a 3000W inverter (made by Max) to run his AC in the trailer. Pretty sweet setup, has a switch on the exciter to charge the batteries when needed. Says it only takes about 20 minutes to fully charge them.

Mike
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Old 06-01-2009, 11:27 PM
TowerRigger TowerRigger is offline
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So looking at this diagram of the pin outs which wire did you put where?

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Old 06-02-2009, 12:32 PM
santacruzf250 santacruzf250 is offline
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cool man, good work! lets see some pics!
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Old 06-02-2009, 01:01 PM
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Awesome writeup.
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Old 06-02-2009, 02:38 PM
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Awsome writeup x2
Another request for Pictures x2.
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Old 06-02-2009, 03:52 PM
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wow, this is one old thread!
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Old 06-02-2009, 04:10 PM
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mongo75 mongo75 is offline
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This is old LOL. Only 11 post, I think that dude is no longer with us ....
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Old 01-05-2010, 05:30 PM
scottownrow scottownrow is offline
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Photos of instalation

Just wondering if i could get some photos of the install i run a Right hand drive vehicle in australia and want to check clearances before ordering brackets from USA
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Old 07-16-2010, 02:16 AM
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pictures please, i was wondering if you can run the dual alternator belt with out 2 alternators? i was told that way you dont have to take off your upper hose to change the serp belt?
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Old 07-16-2010, 03:04 AM
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Quote:
Originally Posted by scottownrow View Post
Just wondering if i could get some photos of the install i run a Right hand drive vehicle in australia and want to check clearances before ordering brackets from USA
Quote:
Originally Posted by b-uno View Post
pictures please, i was wondering if you can run the dual alternator belt with out 2 alternators? i was told that way you dont have to take off your upper hose to change the serp belt?
Don't expect any pics guys. The original post is over six years old.

b-uno,

Get an around the belt upper radiator hose and you won't have to remove it to change the belt.
It is the dual alt upper radiator hose you need, no the dual alt serp belt.
It's not the length of the belt but the routing of the hose.

The new part number for this hose is f81z8260ca

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Old 07-16-2010, 03:30 AM
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Quote:
Originally Posted by PaysonPSD View Post
Don't expect any pics guys. The original post is over six years old.

b-uno,

Get an around the belt upper radiator hose and you won't have to remove it to change the belt.
It's not the length of the belt but the routing of the hose.


THANK U!!!!! that will be great!!
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Old 07-16-2010, 03:38 AM
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The new part number for that upper hose is F81Z8260CA.

See my last post in your "Serpentine Belt" thread.
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