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1996 explorer alt. in 86 5.0 swap

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Old Jun 23, 2020
  #1  
thewoff's Avatar
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From: Colorado Springs,Co.
1996 explorer alt. in 86 5.0 swap

I am using the Exploder front eng. acc. drive from 1996 in my 5.0l swap, my question is how to wire the alt. Alt pigtail has 2 wires(lt. green & Yl/wht ) while the 86 original has 3 wires, I realize that the ammeter cannot be used but the alt end has me somewhat stumped, as Ive seen diagrams on another site,,,,,, I am still at a loss as to the I,S. wires obviously the yellow wire gets connected to th yellow pigtail,
thanks to any and all input!!
 
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Old Jun 23, 2020
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RonD's Avatar
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From: Vancouver, BC
Welcome to the forum

So you have removed the External Voltage regulator from the 1986 vehicle?
That wiring needs to go

The 1996 alternator will have a larger stud/nut terminal(B+) on the back, this needs a larger wire, 8 or 10gauge, this wire will hook to Battery Positive cable thru a Fusible link or a mega fuse, 100-125amps
This is usually hooked up to battery positive cable on the stud/nut terminal on the Starter Relay inner fender
Alternator B+---------------------------------------------fusible link or mega fuse---------------battery positive

The yellow wire would usually have its own fuse, 15amp, and ALSO connect to battery positive, and you can do that at the alternator, inline fuse to B+
B+ and the yellow wire should have 12volts all the time, thru fusible links or fuses
Alternator Yellow wire---------------------------------------------15 amp fuse---------------battery positive

The light green wire is the ON/OFF switch for the alternator, it needs Key ON 12volts, 0volts key off
This was used for a Battery Light in the cab
With key ON, the Light Bulb would get 12volts on one terminal and the other bulb terminal was the Light Green wire, when engine is off the alternator is a Ground, so Battery Light would come on with Key On
When engine is started then alternator is no longer a ground, so Battery light goes OFF, if alternator stops working then Battery Light comes back ON

Alternator Light Green wire-----------------------------------------------------------------------------------12v bulb------------------------12v Key on

You do not need the Battery Light, but nice to have, you can use any Key ON 12volt wire in the engine bay, but add an inline fuse 5amp, the Bulb acts as the fuse on the above setup

 
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