need help on installing new alternator
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New User
Joined: Dec 2005
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need help on installing new alternator
Hi
I have 91 aerostar v6 4.0 with factory alternator. I has 2 holes for plugging harnesses in, which are the regulator harness and the alternator harness which i assume connects to the fender mounted starter relay located next to the battery.
The new alternator i got is a 3g 200 amp from motorcityreman
http://www.motorcityreman.com/aerostar-3g.html
This one is a little different. When viewed from the back left to right is the plugin site for the voltage regulator in the the middle is i dont know what there is metal lead inside, what to attache i dont know, and lastly below to its right is what looks like a positive battery post. But how do wire this whole contraption
Any help or suggestion would be great. thanks
I have 91 aerostar v6 4.0 with factory alternator. I has 2 holes for plugging harnesses in, which are the regulator harness and the alternator harness which i assume connects to the fender mounted starter relay located next to the battery.
The new alternator i got is a 3g 200 amp from motorcityreman
http://www.motorcityreman.com/aerostar-3g.html
This one is a little different. When viewed from the back left to right is the plugin site for the voltage regulator in the the middle is i dont know what there is metal lead inside, what to attache i dont know, and lastly below to its right is what looks like a positive battery post. But how do wire this whole contraption
Any help or suggestion would be great. thanks
Posting Guru
Joined: Jul 2004
Posts: 2,416
Likes: 1
From: Mitchell, SD
Welcome! 
Woa, a 200amp alternator!
The stock alt is only 90amps and most people just upgrade with the Explorer 4.0L alt (130 amps.)
Are you running a giant sounds system or something that pulls alot of juice out of the system?
If not, than that is some major overkill. And might overkill your wire harness.
Plus I don't believe that the 3.0L and 4.0L alts have the same bolt/harness design. (I don't have my manual in front of me,) so I don't know how they could sell one universal alt for both the 3.0 and 4.0.
Could you provide a pic of the back of the alternator you got from them?
The "positive battery termanial" on the back should screw on to supply recharge to the battery and system, and the plug is part of the regulator/gauge/ect. It is hard to be sure without actually seeing it.
Woa, a 200amp alternator!
The stock alt is only 90amps and most people just upgrade with the Explorer 4.0L alt (130 amps.) Are you running a giant sounds system or something that pulls alot of juice out of the system?
If not, than that is some major overkill. And might overkill your wire harness.
Plus I don't believe that the 3.0L and 4.0L alts have the same bolt/harness design. (I don't have my manual in front of me,) so I don't know how they could sell one universal alt for both the 3.0 and 4.0.
Could you provide a pic of the back of the alternator you got from them?
The "positive battery termanial" on the back should screw on to supply recharge to the battery and system, and the plug is part of the regulator/gauge/ect. It is hard to be sure without actually seeing it.
Thread Starter
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New User
Joined: Dec 2005
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yeah as a matter of fact I am, 3 amps total of 12 speakers, power inverter for the 17inch flatscreen, a bunch of aftermarket lights, not to mention a whole lot of crap plugged into my cigarrete lighter. Here are links to the pictures I posted on myspace since i dont know how to attache pics yet
http://viewmorepics.myspace.com/inde...68355C49544309
http://viewmorepics.myspace.com/inde...68355C49544309
http://viewmorepics.myspace.com/inde...68355C49544309
http://viewmorepics.myspace.com/inde...68355C49544309
Lead Driver
Joined: May 2003
Posts: 9,303
Likes: 48
From: Lyndonville, Vermont
You need to get some conversion data from whoever you bought the alt from.
The big wire goes to the lug on the back. That wire you have to change to a 4 ga wire and add a 175 amp fuse or so and go right to the battery with it. Don't use the wimpy wire that came with the van or the fuseable links on that old big wire.
Dick
The big wire goes to the lug on the back. That wire you have to change to a 4 ga wire and add a 175 amp fuse or so and go right to the battery with it. Don't use the wimpy wire that came with the van or the fuseable links on that old big wire.
Dick
Senior User
Joined: May 2004
Posts: 159
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From: Lubbock, TX
Does the wiring harness handle the Explorer alt ok, without any mods?
I ask becuase I once had an 87 Mustang, and I used an upgraded higher-output alt in it, and it melted the harness the first time, and it was only about 15 amps higher that original...???
I ask becuase I once had an 87 Mustang, and I used an upgraded higher-output alt in it, and it melted the harness the first time, and it was only about 15 amps higher that original...???
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Postmaster
Joined: Sep 2003
Posts: 4,452
Likes: 1
From: Southern California
Originally Posted by DaveMac2Vans
This is nice to know. If I replace the stock unit, can I just bolt on the 130-amp on my '94 or '92 Aerostar 3.0?
The 3.0L alternator is different from the 4.0L. If you have a 4.0L, a 130A alternator from an Explorer would fit without a fuss, but I have never done that for a 3.0L.
Torro:
On your picture of the old alternator here are the wires:
1) The big wire that goes to the red plastic is the B+ wire which goes to the positive battery terminal.
2) The big connector on the left is for the voltage regulator. The old and new alternators should be the same there.
3) The single wire connector in the middle is the stator wire, which is used by the regulator to regulate DC current through the stator, hence controlling the output of the alternator. That wire should go to the stator terminal on the new alternator.
With all that said, as stated by others already, beef up the battery wire or you'll risk melting the current wire, which is not designed to carry
200A.Maxwagn:
It was OK for me since I only upgraded the alternator to drive the electric fan I put on to replace the stock fan/clutch combo. Instead of upgrading the battery wire, I just slapped on a 30A fuse and ran an 8 gage wire from the alternator to the fan directly.
Last edited by copper_90680; Jan 3, 2006 at 11:32 AM.
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Post Fiend
Joined: Oct 2005
Posts: 5,242
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From: Kiev, Ukraine
Originally Posted by torro4000
ill do that thanks/ but should i run directlyu to the battery post or run it like the old harness where it connecs to the starter relay next to the battery?
Here you can see my connections:
Original wiring diagramm:
But additional headlight (2x200Wt ~ 32 Amp), dual electric fan (140+280 WT ~ 35 Amp) are connected directly to the 8 mm lug. I have Bosch 185 Amp Alternator with external voltage regulator. Principally it's possible to have 2 alternators and 2 battaries, but it's reccomended, if you have electric AC compressor, but its expencive and not popular here (it is not so hot in summer).
Be sure, that connections are good, and I recommend you to use soldering.
It is a good idea to use 200 Amp alternator, original is good, but as for me, 100 amp is not enought.
Lead Driver
Joined: May 2003
Posts: 9,303
Likes: 48
From: Lyndonville, Vermont
The reason for going to the batt is its another connection and everytime you use another connection thats resistance and a place for a problem, It probably won't matter but I gave you the ideal situation. I bought those gold batt connectors from autozone so I have lotsa outputs on my 12 term.
Dick
Dick
