Alternator Suggestions
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Elder User
Joined: Mar 2008
Posts: 816
Likes: 2
From: Sandy Hook, CT
Alternator Suggestions
I replaced the alt in my '96 5.8 F250 about 3 years ago with an aftermarket rebuilt unit. It always seemed to be underpowered to me. On occasion the red battery icon would come on but if I revved it it tended to go away. It never killed the battery, but when a load was put on it, say turning the HVAC fan on high, the lights would dim and the ALT needle would go low. Basically I think this unit was underpowered right out of the box. Does anyone have the correct part # for the replacement alternator for this truck? Again, 1996 XLT, 5.8 auto 4x4 w/AC, all power options. TIA
Fleet Owner
Joined: Oct 2005
Posts: 20,786
Likes: 1,751
From: Kentucky
The factory alternator on these trucks is rated for ~95 amps. Yours should be a 3G so it should not fall prey to low output at low RPMs. I suspect and agree with you the aftermarket is most likely faulty.
With that said I would not install a factory 95 amps alternator. Go for one off a Taurus/Windstar/etc. that is rated for 130 amps. Upgrade the charging cable and fuse accordingly. You will never have the issues you previously described.
With that said I would not install a factory 95 amps alternator. Go for one off a Taurus/Windstar/etc. that is rated for 130 amps. Upgrade the charging cable and fuse accordingly. You will never have the issues you previously described.
Senior User
Joined: Sep 2016
Posts: 219
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Did the trucks that came with the 130 amp alternator even have larger wiring?
Fleet Owner
Joined: Oct 2005
Posts: 20,786
Likes: 1,751
From: Kentucky
I do not think these trucks ever got the 130 amp alternator from the factory. Therefore, no to your question.
Junior User
Joined: Aug 2014
Posts: 72
Likes: 3
If you have the 95 currently, Is it a straight bolt-in swap? No wiring changes?
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Senior User
Joined: Sep 2016
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For some reason I thought it was optional on the 300.
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Cargo Master
Joined: May 2001
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Go ahead and put the Higher amp alternator on. The charge wire has fusible links where it connects to the solenoid. Probably 2 12ga links. Which means the circuit is protected. 130 amp would need a #1 wire. Never seen any car maker put that size wire on the alternator. Maybe a #4.
Senior User
Joined: Jun 2016
Posts: 354
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From: Ar
this is what I used on mine/ 7768HP-240A 240 Amp High Output Alternator for 1992-2004 Ford Pickup, SUV, Van 4.0L - 7.3L
5th Wheeling
Joined: Oct 2010
Posts: 48
Likes: 0
From: Florida
Worth a check...Diameter of the pulley is critical as the design rpm for alternator must rotate with proper engine/alternator RPM ratio.
I only mention this cuz I bought a rebuilt once...and had sort of the same problem..turns out the pulley ended up to be almost 1/2 inch less in diameter than the original
It made the difference
I only mention this cuz I bought a rebuilt once...and had sort of the same problem..turns out the pulley ended up to be almost 1/2 inch less in diameter than the original
It made the difference
Fleet Owner
Joined: Oct 2005
Posts: 20,786
Likes: 1,751
From: Kentucky
You increased the amperage capability by ~50%. It's silly to keep the same size charge wire since it was marginal for 95 amps.
Just my opinion
Just my opinion