https://www.dieselpowerproducts.com/...rd-powerstroke

I got this when it was 390 or so. It's expensive, and you need to figure out the glow-plug situation, but it's far far more efficient than any other option so it'll last longer and use less HP from your motor than the other options.

 

That is a 2008 Ford Super Duty alternator with a revised voltage regulator and an oval to d shell translation harness. It is a segmented conductor (Denso hairpin flatwire) winding with 6 internal phases. It uses the same winding technology that powers the genuine Denso starters.

For over a decade, boutique aftermarket alternator resellers have marketed this alternator as a custom or specially built unit, but if Ford hadn't decided to OEM the Denso alternator in a 3 bolt T mount case, it would not exist.

To hide the fact that this is a 2008 Ford truck alternator, DC Power went so far as to have custom billet drive end frames (the outer ventilated case) made, instead of using the original aluminum casting for the same.

This is a good alternator. There are two stator diameters available. Even the largest stator diameter is still smaller than the LARGE case 6G of 140 amps that people often upgrade to. That gives you an idea of just how electro-mechanically efficient the Denso segmented conductor density per amp rating of performance is. Pound for pound and millimeter for millimeter, no other alternator for this application can beat it for power factor to form factor ratio.

The larger diameter Leece Neville (230 amp) and the OBS Mitsubishi ambulance package alternator (215 amp), while slightly less in amp rating, are significantly heavier in weight. If I recall correctly, the Mitsubishi alternator weighs 35 lbs. So the marvel of the Denso alternator is how much electrical power generation it can pack into the same form factor as the 110 alternator.

That all being said, larger case diameter alternators have the physics that support heat rejection. So in all things there is a balance to be considered between sometimes mutually exclusive concerns in competition with each other.

One can buy a 2008 Ford Denso alternator for $200. One just needs the know how to change regulators, as the 2008 alternators are PCM controlled, whereas the 7.3L diesel alternators are not. The third wire in a 2008 alternator (center position) is actually used in 2008, but is not used at all in any 1999-2003. The translation harness is available from alternator supply shops.

Due to the small form factor, I will build one of these for my lower alternator, in the event the DelcoRemy that I have in the lower alternator position now ever fails. That might never happen, because I have the big black Leece Neville on top, so the loads are light and shared between both.

 

Has this conversion been documented? I was interested in doing it myself but couldn't find documentation... also this is when I thought my engine would be back together soon.

 

370 amp Denso alternator, meet 8 tired Autolite glow plugs!

 

Last Friday afternoon I dropped off the alternator at the rebuild shop and yesterday I picked it up and today I put it back in. Two new bearings and a voltage regulator and he said the rest of it looked fine. Does seem to have quieted down some extra noise I was hearing under the hood so for $80 I'm going say it's as fixed as it needs to be. I think I wasted more than that in non-refundable shipping charges on the two others I sent back and the ridiculous 20% restocking fee that Quickstart charged me. Oh well...wasn't in the mood to get fancy or complicated with this one but now have some piece of mind at least.