6.0 Single Alternator system replacement upgrade?'s - TheDieselGarage.com
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Old 08-02-2011, 02:10 PM   #1
battterup
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6.0 Single Alternator system replacement upgrade?'s

I have a 2004 F250 SD 6.0 Powerstroke and the single 110 amp alternator needs to be replaced/rebuilt. I am told the stock 135 amp top alternator of the 04 dual alternator system will work as it's replacement for an upgrade to a higher output alternator in it's place by a local reputable Independent alternator repair shop owner. But, I noticed the pulley diameter is different in my investigating the specs- The 110 amp has a 69mm pulley while the 135 amp has the 71mm pulley. Anyone know or had success in using the 135 amp top alternator to replace the 110 amp alternator by just changing the pulley? Also, Will the 135 amp top alternator (dual alternator system) perform with the OE ECM that is designed for the 110 amp single alternator system without changes needed to the ECM settings?
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Old 08-02-2011, 06:21 PM   #2
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The PCM in a single alternator truck does not communicate w/ the alternator. You do not need to worry about compatability w/ the PCM in your decision of which alternator to buy.
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Old 08-02-2011, 09:06 PM   #3
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I would want to know that the output at idle is the same or better. Just because the peak output rating is higher doesn't mean the idle output is. I would be concerned that it is in fact reduced to accommodate the combined charge output of two alternators from the dual system. At the bare minimum, the pulley difference is an indicator that an engineer saw a need to slow it down slightly (3%). Your alternator repair shop should have a test stand to verify the outputs and be able to give you some additional insight.

Amps are like torque in the electrical system, if they aren't available where you need them, they aren't of much use to you.
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Old 08-03-2011, 01:31 AM   #4
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I put on a 220amp HD unit and love it.
Here is some great reading and links.
http://www.thedieselgarage.com/forum...ad.php?t=92173
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Old 08-03-2011, 06:21 PM   #5
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Look up DC Power INC I have their 270amp alternator. You will need to upgrade the cables along with it but you never have another problem again. The problem with pumped up stock sized case alternators is HEAT and that will destroy the diodes in due time and you will be again replacing what only seems like a better alternator again.
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Old 08-03-2011, 06:25 PM   #6
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Quote:
Originally Posted by F350R View Post
Look up DC Power INC I have their 270amp alternator. You will need to upgrade the cables along with it but you never have another problem again. The problem with pumped up stock sized case alternators is HEAT and that will destroy the diodes in due time and you will be again replacing what only seems like a better alternator again.
They are great aren't they?

I have the 250A and love it!
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Old 08-04-2011, 04:27 AM   #7
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Appreciate the info F350R. Thanks for the help
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Old 08-04-2011, 05:23 AM   #8
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Appreciate the help guys.

After reviewing the info of alternatorparts.com,and contacting the owner in the demo video, I decided to return the purchased Autozone alternator and ditch the lifetime warranty plan altogether and go with his larger housing unit and it's new components. Better quality and deal, cooler running, less likely to have to have to replace this one as soon as the smaller case OE 110 or 135 amp remanufactured alternators. Plus it appears he will service this quickly should the need arise. 1 year warranty keeps the price affordable and Getting it here in a couple of days is a plus. "The smaller 69 mm pulley is used on all the 6G Series alternators offered at alternatorparts.com" I was told for increased idle output amps.
The 185 amp from DCPowerInc is just 40 bucks more shipped but delivery of 2-3 weeks leaves me wondering How long will I be waiting for a replacement in an emergency situation. My old retiring alternator is good for a back up but I don't want to consider using it for more than a week. Either way, both companies look good and the 140 amp unit meets my needs for this workhorse. Thanks again and now I will need to address the issue of tuners for this ride to get the power with less throttle and fuel mileage up. Any help is appreciated on getting the best tuner "bang for the buck" here
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Old 08-04-2011, 05:51 AM   #9
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Quote:
Originally Posted by battterup View Post
now I will need to address the issue of tuners for this ride to get the power with less throttle and fuel mileage up. Any help is appreciated on getting the best tuner "bang for the buck" here
SCT with custom tunes is the way to go with the 6.0. But before you start adding power, you should get gauges/monitor first.
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Old 08-04-2011, 10:30 PM   #10
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Quote:
Originally Posted by lilpooh View Post
SCT with custom tunes is the way to go with the 6.0. But before you start adding power, you should get gauges/monitor first.
Looked at the Hypertech 42002 Max Energy Power Programmer, Superchips 1855 Flashpaq Tuner , Bully Dog units already and gauge kits.

My thinking is having also Exhaust temp gauges is best with a tuner that includes the monitoring kit - 2 sensor unit. Havent researched them all yet but looking at the SCT options for this truck looks good. Any particular dealer locations to get the best deal on their units and where is the best bang for the buck in gauge units that include Ex temp gauges?
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