Upgraded alternator
Tuned
Joined: Oct 2013
Posts: 293
Likes: 119
TIME SINCE KEY ON CURRENT
0 seconds 150 A
5 seconds 75 A
10 seconds 60 A
20 seconds 50 A
50 seconds 42 A
So, the glow plug only exceeds the continuous rating of the wire for less than five seconds according to this data. The ability of a wire to tolerate a current draw in excess of its continuous rating is an inverse exponential, which you can see in the thermal portion of the trip curve for a circuit breaker:
The size of the wire also very likely was signed off on by an engineer, that engineer worked for Ford.
Fleet Mechanic
Joined: Mar 2017
Posts: 1,365
Likes: 179
From: Phenix City, AL
I went another direction with my alternator swap: pre-‘99 7.3 version. It’s been 9-months of trouble-free alternating. https://www.ford-trucks.com/forums/1...ator-swap.html
Lead Driver
Joined: Jun 2013
Posts: 5,647
Likes: 891
From: north of Minneapolis, MN
Sounds like a 6.0 alternator would be a good candidate for you. I have one on mine. There 135 amps and pretty much bolt right up. On some you have to clearance the alternator bracket very slightly at the bottom. Wiring is the same. I got mine off rockauto. A brand new Bosch unit. There $173 on there today part # is al7606n
FTE Leadership Emeritus
Joined: May 2014
Posts: 27,348
Likes: 5,941
From: Lake Hartwell, GA
Seriously though, if the Bosch 6.0L alternator is larger than the OEM, which I believe it is, you will need to grind a bit of the bracket down toward the front of the engine. This has been going on for years and years and some have installed washers in order to gain the additional clearance.
It is an alternator, nothing super technical or mechanical about it regarding removing or installing.
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Mountain Pass
Joined: Dec 2022
Posts: 152
Likes: 56
Got it, just wanna make sure I don't have to make a new pigtail or source a pulley from a 2003 1/2 expedition
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Lead Driver
Joined: Jun 2013
Posts: 5,647
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From: north of Minneapolis, MN
Mine was 1N-3169
Tuned
Joined: Jun 2007
Posts: 431
Likes: 66
I had a good local alternator shop rebuild a 6.0 with heavy duty parts. I had to grind the lower area of the mounting bracket for clearance, no pics available. Have not had any issues. The 6.0 unit is larger than the OEM and handles heat much better. Go for it!
Super Moderator
Joined: Dec 2011
Posts: 13,286
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The Bosch 140A large case 6G alternator is in the middle of the photo above.
The grinding of the alternator bracket is not so much due to the girth of the alternator, but due to the location of one of the alternator's case body bolts at 6 oclock.
When Leece-Neville designed the Ford 3 bolt T mount case for the AVi160 series rotating assembly, Leece Neville changed the clocking of the case mounting screws, shifting the triangle of bolt point locations around the clock face such that no bolt is directly at the bottom of the alternator, unlike the small case and large case 6g.
The shift in case bolt location enabled Leece Neville to fit a much larger stator and rotor within the Ford mounting bolt specifications on center.
Thus, even though the Leece-Neville is much larger than the large case 6g (most popularly embodied by the Bosch version), the Leece-Neville requires less grinding of the alternator bracket, and no grinding is needed in the center V of the bracket, where it is potentially weak by formation.
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