How To Upgrade Your Jeep Cherokee XJ Alternator

In todays video I upgrade my jeep Cherokee stock 90 amp alternator to a 160 amp alternator from a 2002 Dodge Durango. I also upgrade the charge back wire to a larger wire with a fuse. the stock charge back wire has a fusible line in it which is underrated for this 160 amp alternator.
Next week I will be doing a "big three upgrade" on the xj.
links to the products I use are down below
10pcs 2/0 Gauge x 5/16” Cable Lug Terminal Ring Connectors with Dual Wall Adhesive Lined Red + Black Heat Shrink Tubing - amzn.to/344KgB6
2/0 Gauge 2/0 AWG 10 Feet Red & Black Battery cable,10pcs of 3/8" Cable Lug Terminal Connectors, 3 Feet Black Heat Shrink Tubing - amzn.to/348xguj
Fastronix 250 Amp MEGA/AMG Fuse Holder Kit -amzn.to/368LKw5
Littelfuse MEG175XP MEGA Slo-Blo Automotive Bolt-Down Fuse - amzn.to/2JuOVVh
TYC 2-13915 160 amp Alternator - amzn.to/2pbcpbd
The Off Road Corner is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to amazon.com.
Music by:
In the Gutter - Pearce Roswell.mp3
Keep Walking - Grant Lamotte.mp3
ES_Mistaken Identity (Instrumental Version) - Martin Carlberg.mp3
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[@danhambrick6331]

Thanks for the links.Did my wire upgrade all ready now wanting to do the alternator.For some reason my Xj came with a 124 amp alternator,this upgrade still tops that....

[@TheOffRoadCorner]

no problem. this was a pretty simple upgrade. haha 124 amp is probably what it should've come with from the factory instead of a 90 amp alternator. i don't know what jeep was thinking when they put a 90 amp alternator on the xj.

[@mellester7885]

Since my 89 MJ is basically the same setup, I think I'll go for the 124 amp alternator and maybe do the 160 on my XJ. Great Video.

[@cratz519]

THANK YOU SO MUCH YOU HELPED ME FIGURE OUT WHAT MY WHISTLE IS IN MY JEEP!! ITS THE ALTERNATOR!

[@TheOffRoadCorner]

You’re welcome man! Thanks for watching!

[@doddgarger6806]

My old grandad would raise an eyebrow to that music! 😆 Nice upgrade 👍 doing it soon with a $49 jy part I figured out by chance how to make terminals diy with refrigeration copper line I had cut off of a mini split line, it's soft and solders really nice

[@RedZAgs193]

Very good DIY alternator upgrade with wiring too! I'm going with the jeep cables wiring upgrade but impressed how you pieced yours together. Keep it up good to see a new XJ channel around.

[@TheOffRoadCorner]

Michael Riviere thanks for subscribing. Jeep Cables is a great option for this upgrade. I probably would have got the cables from them but I wanted to up the size quite a bit and change some of the lengths of wires. Thanks for watching

[@dirtysouthtv2209]

The Off Road Corner Jeep Cables have, 4, 2 and 1 gauge kits.

[@thecherokeechannel688]

Had watched your video some time back and I finally got my 160 amp to drop into my own turd. Thanks for the info bro.

[@TheOffRoadCorner]

No problem man! Glad my video could help

[@psiiota6004]

Dude you deserve more viewership!

[@dwitcraft]

Great work. Thanks for the thorough discussion of the fuse link and the loads.

[@TheOffRoadCorner]

David Witcraft thanks man! Thanks for watching

[@constructiontech1970]

Nice job! This mod is now on my list for my XJ!!

[@TheOffRoadCorner]

Thanks! it's a great foundation for any future upgrade that is taxing to the electrical system.

[@richardcraig2937]

Ordering the parts, will be over shortly for some extra guidance...LOL...honestly though, thanks for the vid, links, and some helpful info, keep it up.

[@TheOffRoadCorner]

Thanks for watching. I’m glad my video could help you. I’m here to help.

[@marioorta7825]

Nice work easy up grade ..well you made it look easy lol..appreciate that install amd how too.I see your at 191k nice!!! Im at almost 300k same everything no rebuild yet.

[@Smokevolt]

Exactly what I was looking for. Killer tunes to boot

[@skarlos23]

Hello what year is the durango and what size engine does it have thank you

[@tomodonnell5738]

Hey thanks great info and video. Will this work for 1996 Cherokee?

[@mikecarr1484]

Nice seen this done 3 ways . This is the least invasive. One involved shaving the alternator down. Haha I laughed at that one. This is better idea . Than shaving down the alt

[@TheOffRoadCorner]

Yeah I agree. I saw a video here on KZbin that a guy did that. I couldn’t believe someone would do that a new alternator and expect it to last hahaha

[@hectorhuerta6436]

Question for the alternator connecter will it be the same

[@jeremyhanna3852]

Jeep dealer parts gut here that fusible link is rated for 120 amps per the specs sheet

[@MichaelSmith-qh5hr]

Awesome Video! I have the 160 amp alternator and have modded the brackets. The original alternator came had two wires (Red and Black) around 16 gauge with lugs on them that were held onto the back of the alternator with two small lock nuts. I bought a pigtail for the 160 amp alternator, but I don't want to damage anything by connecting them to the pigtail incorrectly. Can anyone share how to connect the pigtail correctly?

[@anarchistgreg4689]

What year Jeep is this? Mine is a 96 and the wiring does not look the same.

[@LiTtOTOnYAkaShoRty]

What year xj? All years?

[@hectorhuerta6436]

Is it the same connector????

[@ThomasHart59]

That fuse block was never intended to take 180 amps. And just because the alternator may put out 180 max, doesn't mean that would be going into that fuse block, it's all about where the load is. The factory put a fusible link on there of 90 amps for a reason. If you draw 180 through that fuse block, you will definitely melt some stuff, or start a fire. But either way, you'd probably be replacing the harness (or a whole Jeep). The advantage of the bigger alternator is so you can add accessories, but not through the wiring harness fuse block, you'd be doing that directly, or through an additional fuse block. I would strongly recommend that you stick to the factory spec on the feed to that fuse block, its internal connections will probably not survive twice the draw it was designed for.

[@joshdoinggood8117]

Would that alternator work for a 91 jeep cherokee

[@dezertdestroyer7782]

I put a 136 in mine and for some reason it is worse then it was with my extra fan and lights and whatever compared to my 90 I had… so either I need to upgrade the wiring like you did or I got a defective alternator because now my battery doesn’t stay charged where the 90 was working fine other than if I ran my AC with all my lights on it would almost get into the red with the 90…. With this 136 I put in today if I turn all that stuff on it’s only putting out 11.6 V… and all I did was swap the alternators.. which wires do I make bigger? Mine is a 1993… is there one wire that goes to the fuse panel and then the other positive wire goes from the battery to the alternator? 🤷🏼‍♂️🤷🏼‍♂️🤷🏼‍♂️

[@TheOffRoadCorner]

A defective alternator could be possible. I doubt it’s your wires but as much current as this alternator can produce may cause the stock wires to get hot when you have everything on. One thing I’d make sure of would be the engine ground. The alternator is case grounded so you might try hitting the alternator mounting points on the engine with sand paper first.

[@trevorjordan7852]

Do you have to do the wire upgrades

[@rossstevens4820]

Great video, I have been wanting to do this to my 2000 xj, does anybody know of an after market kit for the battery cable replacement? Thank you very much.

[@youruniquehandle2]

Any pointers on tensioning the belt? I never know if I'm overtightened or not tight enough.

[@TheOffRoadCorner]

I always tighten the belt until I think its too tight and then tighten it even more lol. these belts like to run tight so I shoot for about 3/8" of belt deflection between the water pump pulley and power steering pulley when you push down on the belt firmly.

[@danhambrick6331]

They make a belt tension gauge that you push on the belt to measure tension.They are pretty cheap too...

[@burkleyfield2973]

Thanks for this awesome video

[@mikeloomis2091]

Watched your videos awesome upgrade, question will the 10 feet of black and red wire kit do the cables and the alternator upgrade or do I need 2 wire kits?

[@TheOffRoadCorner]

You only need 1 kit to replace all the cables. I used all of the red wire and probably 2/3s of the black that comes in this kit.

[@mrmotorbreathmfg3540]

I followed your link in the "97-01 Jeep Cherokee XJ DIY "Big 7" Battery Cables - Battery Cable Upgrade" video here for the charge back cable you mention. I noticed you didn't post speak about the length of the cable and terminal hole sizes like you did in the big 7 video. Do you by chance know off by hand how long you made it?

[@TheOffRoadCorner]

The cable from the alternator to the fuse is 42” long. From the fuse to the pdc is 7”

[@mikeloomis2091]

I can not find the TYC that you put in your parts list here would any alternator DENSO that fits a 2002 dodge durango work for this?

[@TheOffRoadCorner]

yes it will

[@ggsprock]

Gathering all the stuff to upgrade my 97 XJ. The same year 135A Grand Cherokee alternator is a 1:1 match. Where did you get your solder?

[@TheOffRoadCorner]

I think I got it at Lowe’s in the plumbing section. I bought it years ago and still haven’t made a dent in the spool yet lol

[@ggsprock]

Thanks. I picked up a roll at NAPA. Did the upgrades with a 135A from a Grand Cherokee 4.0L S6. Perfect fit, no grinding. Makes 14 volts just right :-)

[@JoeVizethum]

good video and a clean upgrade, dude ! I still have the original alternator installed in my 1998 XJ and I'm not sure if I need this 160 amps powerhouse as I just will be having some additional headlights, may be a winch in the future. What accessories do you have in place ?

[@TheOffRoadCorner]

I only have the winch for right now. In the future I want to add a bunch of lights, air compressor and possibly a fridge. The 160 is over kill but that’s the way I like it. Thanks for watching!

[@jerrywhalen2100]

Hi new viewer when are you going to be doing frame stiffeners on that XJ I know they're very important because my buddy had a two-door and that thing was breaking windshields because it was flexing so much if you don't have them you should get them

[@TheOffRoadCorner]

Hey Jerry. Yeah stiffeners are very high on my list.

[@downnoutdubin]

Great video! I did my big 3 wiring upgrade a little while back. Did you do anything to upgrade the y link cable to the main harness? I couldn't think of a good method to do so.

[@TheOffRoadCorner]

thanks man. I'm not sure what you mean by the y link cable to the main harness.

[@reebertJunkman]

Thanks FOR A EXCELLENT VIDEO... WILL START THE WIFE UPGRADE NOW AND THE alt A LITTLE LATER

[@codyclements8784]

Did you have to grind on the motor where the two double ended bolts go through for the rear bracket?

[@TheOffRoadCorner]

No not at all. The only grinding I had to do was on the alternator mounting bracket

[@codyclements8784]

@@TheOffRoadCorner right on. I didn’t get so lucky lol. I had to grind that spot to even it up with the rear mounting bracket. Thanks for the video though, good sir!

[@sdkid88]

I thought it was bad to mix up alternators from different vehicles

[@mr.bigfoot550]

I know it is a dumb question but why do you need a fusible link

[@TheOffRoadCorner]

In case the alternator goes full field. The fusible link will burnout before destroying the rest of the electric system.

[@mr.bigfoot550]

@@TheOffRoadCorner oh okay thank you I'm doing the same thing and just wanted to adk

[@smokeymonjes8575]

Dont they make aftermarket 200-300 amp alternators that fit in the xj

[@TheOffRoadCorner]

I have no idea. I've never heard of a alternator with that high of amperage

[@larrywarren1049]

Stereo guys would be the best place to get answer

[@bmac5315]

Awesome video. Would this upgrade work on an 87 xj?

[@TheOffRoadCorner]

I’m not sure. If the mounting brackets on the pre 97 xj’s are different than I would have to say no. But if your mounting brackets look the same than it may work.

[@jackmurphy2589]

I know it's been a while since you've posted this video. But the upgraded wire with the fuseable link, was that what some would call the exciter wire?

[@TheOffRoadCorner]

I’m not 100% sure what a exciter wire is. If I had to guess, It kind of sounds like a older term that was referring to the voltage sensing part of alternator. Those wires on now 2 small gauge wires (16ga)that plug into the alternator and run to the engine computer without a fusible link.

[@seanpm20]

Great video. How much did the Durango alt run you?

[@TheOffRoadCorner]

165.99. Here’s link to the alternator I bought amzn.to/2pbcpbd

[@artyfuffkin7805]

What do you need 160 amps for the starters 110-150 but after that it's 30 ish ,harder to turn a bigger amp alt

[@izzynutz2000]

Will this work on a 93 with the Chrysler computer control voltage regulator?

[@TheOffRoadCorner]

I’m not entirely sure if it will work. To me a voltage regulator is a voltage regulator so it should do its job and regulate the charge from any alternator.

[@jeremyb2907]

Yes external voltage regulator alternator has two field terminals just the plug type. I might do this upgrade on my jeep zj 4.0 have a stereo system. Would like to have a hairpin stator alternator with more amperage. I have an 136 amp on now. It makes a whining noise thinking it could be why my gas mileage had gotten bad.

[@moejr14]

Do you happen to have the p/n for the 160 amp Alternator that came stock in the Durango? I’m hoping to find one at the junkyard.

[@TheOffRoadCorner]

56029915AA I think is the correct one.

[@moejr14]

The Off Road Corner Thank you man, in the video you mention the alternator wire Going to the fuse and then to the battery. Is that correct or is it fuse to Pdc then battery? Or does it not matter?

[@TheOffRoadCorner]

The cable from the alternator gets a fuse and then bolted to the PDC. Sorry if that was confusing in the video.

[@moejr14]

The Off Road Corner so basically the fuse replaces the online fuse, do I absolutely have to go through the pdc or can I go directly from fuse to battery?

[@TheOffRoadCorner]

You could do either really. The fuse is just to protect the Jeep from the alternator if the alternator decides to start over charging the battery.

[@millerzionZ3]

Hey is everything still going good? I wanna do this to my Jeep xj

[@TheOffRoadCorner]

Yeah it’s still working great. No complaints here.

[@millerzionZ3]

The Off Road Corner great !!! Thank for the great video

[@TheOffRoadCorner]

Thanks for watching!

[@seanmcqueen2186]

What did you do for the two pin connector into alternator.

[@TheOffRoadCorner]

It plugs directly into the new alternator.

[@seanmcqueen2186]

The Off Road Corner My 98 Cherokee has a larger two post connector that screws on.

[@TheOffRoadCorner]

@@seanmcqueen2186 ​I did some google searching and it looks like 98 (possibly more years) have a black box connection thing on the back of the alternator. It looks like the 2 ring terminals pointed towards the center of the alternator are for the field windings. If you get a pigtail for the plug on this Durango alternator you can hook the wires from the jeep to the wires on the pigtail. It doesn't matter which wire goes to where. Otherwise, the link below is to a 160 amp alternator that should swap right in. amzn.to/2NTcutq

[@seanmcqueen2186]

The Off Road Corner yep that’s it. Just went to junkyard and cut the two pin connector off a 03 Durango and plugs right in. Just have to splice it and run a ground. Autozone wanted $61 for the plug.

[@TheOffRoadCorner]

@@seanmcqueen2186 Nice! i'm glad that worked out. $61?! WOW Autozone, that's ridiculous!

[@philliptaylor5981]

Did you do the positive battery cable upgrade?

[@TheOffRoadCorner]

Yes I did.

[@coltenmartinelli8730]

Is 2 watt not too big of a wire??

[@TheOffRoadCorner]

its definitely overkill. stock XJ wires are 4 gauge which technically worked but bigger would be better. I don't think i'd go any smaller than 1 gauge tho

[@EcarrTech]

Great Vid I will do my 95 XJ next week. Listen, please send me the list of your music to listen to while I'm working on it.

[@TheOffRoadCorner]

thanks man. Its a great upgrade for a XJ. I put the song names and artists in the description of each video. you should be able to have what songs you like there. i get all my music from Epidemicsound.com

[@Ontheroamagain]

This might be a dumb question..But what is the advantage of this upgrade?

[@Ontheroamagain]

No seriously would this help out with more accessories?

[@TheOffRoadCorner]

David Ochoa the advantage of this upgrade is its ability to recharging the battery from high amp draws like electric fans, large wattage speakers and (my reason for installing it) long hard pulls using a winch. This larger alternator helps the battery recover from larger loads.

[@Ontheroamagain]

Okay cool kinda what I thought just wanted to make sure! Thanks good video! Might have to do this! 👍🏻

[@jacobjms7906]

Would this be the same as a 94 zj?

[@TheOffRoadCorner]

Jacob Jms I’m not 100% it would fit. The alternators look to be the same size as the ZJ but my XJ had a plastic plug in for the voltage regulator. It looks like the ZJ use 2 small studs on the back of the alternator to connect to the voltage regulator. I checked on amazon and there a 160amp alternator option for the 94 ZJ. It looks like a direct swap. Here’s a link - LActrical HIGH OUTPUT 160AMP ALTERNATOR FOR JEEP CHEROKEE GRAND CHEROKEE WRANGLER COMANCHE PICKUP 1991 91 1992 92 1993 93 1994 94 1995 195 1996 96 1997 97 1998 98 2.5 2.5L 4.0 4.0L ENGINES www.amazon.com/dp/B00BITW45G/ref=cm_sw_r_cp_api_i_lzQODbXYQJS3W

[@jacobjms7906]

Thank you, I appreciate the help and guidance.

[@MileHighs]

Will this be the same on a 95?

[@TheOffRoadCorner]

I'm not 100% sure it would be. Just by looking at pictures of both alternators. The 91 to 98 alternators have different connections for the voltage regulators and 2 random studs on the back that my XJ's alternator didn't have. Poking around on amazon I found a 160 amp alternator for the 91-98 4.0l that is a direct bolt-in. And it's cheaper than this Durango alternator. Here's a link to it amzn.to/2NTcutq

[@spawnsrevenge]

@@TheOffRoadCorner that Amazon link says V6

[@jerrywhalen2100]

Any chance of overcharging battery since now the alternator is charging earlier lower RPM

[@TheOffRoadCorner]

I haven’t run into any overcharging. Although it completely untested theory, I think the voltage regulator keeps the alternator in check at all times and RPMs. I want to do a video on actually testing the alternator’s current and voltage output in different situations. I.E idling, 2k RPMs, winching, etc.

[@gregj.gotham4402]

What the hell never heard that before…. Yep I’ll be doing a 160 amp alternator too from a dodge donor vehicle at the junkyard.

[@mikecarr1484]

But they sell an upgraded alt . That has the same terminals ..that's what I used . You just have to modify brackets.

[@TheOffRoadCorner]

that sounds like the same alternator I used. the mounting bracket had to be shaved down a bit and the field wiring plugged straight in.

[@yusufjorgenz5951]

Sky high wire is number 1. Rockford wire is 2. Watched the testing videos

[@williamjwarren3735]

Knukoncepts is number 1 sky high num 2

[@francisbrackney2061]

Your fuse shouldn't blow out from adding a higher amp alternator. What would likely blow the fuse would be excessive draw greater than the limit of the fuse, or a short circuit. Especially a short circuit to positive current to ground situation. Although I absolutely agree with you changing the style of fuse, from a link wire, to a in line fuse.

[@sory4beinanonymous]

Or you can just buy a 160 amp alternator that bolts right on. At least it’s compatible for 87-99

[@flex-jsteve540]

300 amp on mine

[@TheOffRoadCorner]

Damn! That’s a lot of amps.

[@flex-jsteve540]

The Off Road Corner need it with a winch....2/0 runs on it agm battery and big 7

[@TheOffRoadCorner]

Flex-J Steve no doubt about that. The more amps the better because are power hogs. I thought my 160 amp alternator. Yours blows mine out of the water haha.

[@flex-jsteve540]

The Off Road Corner oh you’re better than most for sure but I just go super overkill on everything I do lol my Jeep is on the crazy side I spend heavily and do the work myself

[@TheOffRoadCorner]

Flex-J Steve I like you’re style lol. Over building jeeps and building it yourself is the way I roll too.

[@gregphillips1998]

Just gonna say “Do Not Solder the Ends on Your Cables”. You should always use a high press tool to clamp the ends on. I have personal experience with working as a mechanic. U deer heavy loads over time the solder will melt and give you bad & loose connections.

[@TheOffRoadCorner]

I'd have to disagree with you due to my personal experience is a mechanic. If you're worried about heavy loads melting the solder. Think about how many amps you'd have to be flowing through 0/2 cable to get that connection to heat up to 370deg F to melt the solder. That amperage level is more than my 75 amp hour battery can output. my experience has taught me that loose or bad connections can happen with either method if not done properly.

[@StevenTrevino-r6n]

Will this work on a 93xj