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[updated:LAST EDITED ON 13-Nov-02 AT 10:48 PM (EST)]What is the biggest alternator I can get for my 90 Bronco with a 351W? The largest I have seen is 100 amps. Now that winter is here when I have my heater on full blast my electrical guage is jumping all over. I know that these guages are mostly symbolic, but I can watch my headlights and interior lights dim at idle. The battery is in good shape, and I have replaced the alternator a couple of times and it has always done this. So I figured I would step it up and get a bigger one.
Also how can I tell how many amps the current alternator is?
First thing I would do it get the alternator tested for free at most auto parts store. Here, they will tell you the output of it.
I would say the main concern should be the Voltage regulator and its connections.
Clean the Ground mounting screws and V/R back> seal with Di-electric grease.
Also clean the V/R contacts and put a small film of di-electric grease on them.
Now hook it all back up set your idle to spec and have a look at the charging system.
[updated:LAST EDITED ON 13-Nov-02 AT 11:27 PM (EST)]
The voltage regulator is inside the alternator on my Bronco, and the alternator has been replaced a couple of times, so I don't think it could be that. It has always done this, so if it isnt a lack of amps what else could it be? Maybe the wiring has crapped out? Maybe the heater blower motor is pulling too much current? If so how do I check that?
I will clean and grease the connections like Dennis said and see if that will help.
[updated:LAST EDITED ON 14-Nov-02 AT 02:34 AM (EST)]This is assuming that your blower motor runs all the time and the problem is worst or exists when the motor is running.
The blower motor is inherently a high-draw accessory especially when its running on high speed. Something you can check though is the condition of the motor. I have never pulled mine, so I can't give instructions as to exactly "how-to" but, I can tell you that if the draw from the blower seems inordinately high, pull it and give it a spin by hand. It should spin freely for many revolutions. If it doesn't or there seems to be more friction or drag on the motor armature than there should be, chances are one of the field magnets has seperated from the motor casing. Solution replace the blower motor. I had this happen to the wiper motor and every time it rained, I was losing electrical power terribly. I thought it was humidity/moisture somewhere it shouldn't be. Turned out the loose field magnet was dragging on the armature and creating enough drag to make the motor HOT to the touch. I opened the motor for SH**s and giggles only to discover the one field magnet half worn away from dragging on the armature.
The loose magnet won't necessarily produce any greater noise than a good motor will either
Also, as for the terminals, look at this:
http://www.nastra.com/images/tech107.htm
also, look at the various ground cables; batty to frame/eng., engine to frame, etc. and the little cable that grnds the PCM (I believe your year has one at the batty harness, but could be wrong).
Thanks for all the help so far, I will try to track this problem down this weekend. Now I have to worry about trying to fit my Bronco into my tiny one car garage, it will fit but there isn't much room to spare on the sides :-( I will check the wires and grounds first, if that doesn't do the trick I will pull the blower motor out.
The blower motor takes like 15 minutes to pull out. It is located right by the passenger side hinge of the hood, inside the engine compartment. I replaced mine becase it was doing the same thing and making noise unless I had it on full blast. Turns out that the fan was full of dirt and it was causing the motor to run harder. A replacement Siemens motor from Napa costs around $30.
THere are three nuts holding it in. Just pull those out and you will see the fan and the motor, it is pretty straight forward, I think it took me all of 20 minutes. At the auto parts store the guy suggested that I buy a new fan too but it was a waste of money, the old fan is better quality it just needs to be cleaned up some.
If you're really gungho on changing out the alternator for a stronger one, what I did on my ex-bronco (1983 I6) was get a 100 amp alternator out of a Taurus, swapped the pulleys over, and bolted it in. Had to get a different v-belt and was a little harder to put the belt on (since the casing was bigger) but other than that it fit with no problems. Course I would still check on bad wiring and stuff like that first. I just needed the extra juice for an amp and some fog lights. Shouldn't be any harder to make it work on a serpentine belt though. Good luck.
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