ArizonaXJ
08-27-2007, 05:15 PM
OKay, here we go. I'm reinventing the wheel again but, WTH?
So, a few months ago I decided that I HAD to get more juice in the old Cherokee's electrical system.
Hundred watt off-road lights, winch, electric fan, etc. was starting to takes it toll. Now, I did some research here and on other websites about how to do this. The one thing that I wanted (needed to really) to stay away from was 1. A really expensive after market alternator and 2. An inexpensive but nightmare to wire up alternator.
That left me trying to find something within the Chrysler/Jeep/Dodge line up.
Well, I found it......
You can go to Autozone and get Part number 13387. It is a 136 amp alternator for a 97/98 ZJ (Grand Cherokee) with the 5.2 liter engine.
I am sure that Checker or any other parts store will have this but I am not sure what the part number will be.
The cost for this alternator is $149.99 + tax and a $90.00 core charge. They will accept your puny 90 amp as the core. This is the lifetime warranty one. Also, if you know of someone with a military I.D. card, take them with you. Checker and Autozone does give military discounts!!!:D
Now, as was stated in other alternator swaps along this line, the 136 amp one does have a slightly wider pulley. This is no problem to worry about. Just make sure that when you install the belt that you set is as far back on the pulley as possible. That 1-1.5 mm extra does not interfere with anything or even come close.
The wiring is straight forward. It goes on just your old 90 amp one. No differences.
The one and only catch to all of this and it was NOT mentioned in any of the articles that I read was the alternator mounting bracket itself. It is TOO SMALL to hold the 136 amp unit.
You will need to take an angle grinder to it so that it will fit around the 136 amp unit. What you will need to do is remove the entire bracket form the vehicle. Set one of the alternator bolts into the alternator and the bracket as if you were installing it in the vehicle. Once you do this, you will see how much material that you need to take off from the bracket. It will hit the side of the alternator's housing until you get enough material removed from it. When you have enough material removed, all of the bolts will line up and go in without hitting or binding anything. Once you have enough clearance for the 136 amp unit, bolt it in just like you would any other unit into the vehicle.
Now, I know there are other ways to approach this but this was by far the easiest and most economical way that I found.
Since I didn't take any pictures of my work when I did it. I made a couple of drawings to sort of aid in my explanation and attached as a word doc.
***One word of warning**** WHEN REMOVING MATERIAL FROM THE BRACKET, DO NOT, DO NOT TAKE ANY MORE OFF THEN NEEDED TO CLEAR THE NEW ALTERNATOR!!!! YOU ARE WEAKENING IT AS IS BUT NOT TO THE POINT OF REALLY HAVING TO WORRY ABOUT IT. REMOVING MORE MATERIAL THEN REQUIRED IS ASKING FOR BREAKAGE.
With all of this being said. I will gladly help anybody out with this project. It doesn't take too long to do. The big pain in the butt is gradually removing the material away from the bracket.
So, a few months ago I decided that I HAD to get more juice in the old Cherokee's electrical system.
Hundred watt off-road lights, winch, electric fan, etc. was starting to takes it toll. Now, I did some research here and on other websites about how to do this. The one thing that I wanted (needed to really) to stay away from was 1. A really expensive after market alternator and 2. An inexpensive but nightmare to wire up alternator.
That left me trying to find something within the Chrysler/Jeep/Dodge line up.
Well, I found it......
You can go to Autozone and get Part number 13387. It is a 136 amp alternator for a 97/98 ZJ (Grand Cherokee) with the 5.2 liter engine.
I am sure that Checker or any other parts store will have this but I am not sure what the part number will be.
The cost for this alternator is $149.99 + tax and a $90.00 core charge. They will accept your puny 90 amp as the core. This is the lifetime warranty one. Also, if you know of someone with a military I.D. card, take them with you. Checker and Autozone does give military discounts!!!:D
Now, as was stated in other alternator swaps along this line, the 136 amp one does have a slightly wider pulley. This is no problem to worry about. Just make sure that when you install the belt that you set is as far back on the pulley as possible. That 1-1.5 mm extra does not interfere with anything or even come close.
The wiring is straight forward. It goes on just your old 90 amp one. No differences.
The one and only catch to all of this and it was NOT mentioned in any of the articles that I read was the alternator mounting bracket itself. It is TOO SMALL to hold the 136 amp unit.
You will need to take an angle grinder to it so that it will fit around the 136 amp unit. What you will need to do is remove the entire bracket form the vehicle. Set one of the alternator bolts into the alternator and the bracket as if you were installing it in the vehicle. Once you do this, you will see how much material that you need to take off from the bracket. It will hit the side of the alternator's housing until you get enough material removed from it. When you have enough material removed, all of the bolts will line up and go in without hitting or binding anything. Once you have enough clearance for the 136 amp unit, bolt it in just like you would any other unit into the vehicle.
Now, I know there are other ways to approach this but this was by far the easiest and most economical way that I found.
Since I didn't take any pictures of my work when I did it. I made a couple of drawings to sort of aid in my explanation and attached as a word doc.
***One word of warning**** WHEN REMOVING MATERIAL FROM THE BRACKET, DO NOT, DO NOT TAKE ANY MORE OFF THEN NEEDED TO CLEAR THE NEW ALTERNATOR!!!! YOU ARE WEAKENING IT AS IS BUT NOT TO THE POINT OF REALLY HAVING TO WORRY ABOUT IT. REMOVING MORE MATERIAL THEN REQUIRED IS ASKING FOR BREAKAGE.
With all of this being said. I will gladly help anybody out with this project. It doesn't take too long to do. The big pain in the butt is gradually removing the material away from the bracket.