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  #1  
Old 06-05-2007
KARPE's Avatar
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New Alt. install question

I have a 200amp Alternator waiting to be installed. I need to know if I should go with 4g wire or 1/0g wire. and approx. how much will I need.

Also is there any reason I couldn't use something like this
http://www.cardomain.com/item/MON120969

I have very limited time to change out the Alternator and wiring, so I can't afford to be making trips back and forth to parts stores or wait for shipping on forgotten parts.

is there any other information someone could offer that would speed this process up?

Last edited by KARPE; 09-17-2007 at 02:35 PM.
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Old 06-05-2007
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4ga is the minimum I'd use for a 200a alt. (most of the places that sell them recommend 4ga ot 2ga as I remember)

You're probably going to need one piece at least 5' long to go from the alt over to the battery (at least I did on my '96 4.0 v6)

I opted to go with 1/0ga from the alt to fuse, fuse to starter relay, starter relay to battery; starter ground to frame, frame to body & body to battery negative... then 1/0 in to my distribution block for my amps, accy's.

I had to modify my battery terminals to accept two 1/0ga wires, but it worked out well. (I've been meaning to get pics of my install, but I just haven't had time...)

I believe I bought 30' total of 1/0ga and I had about 2' left over.

You might be able to find some 4ga butt connectors to add a couple of those 3' sections of 4ga together, but I don't recommend splicing large wire together.
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Old 06-05-2007
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I figured I would need at least one large one. My next day off is a week from today so I am gonna see how many people needed around 30 feet as well. where did you buy your wire from?
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Old 06-06-2007
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I got mine from knukonceptz.
Their copper clad aluminum wire is what I used, it is slightly larger than 1/0ga wire but it's about half the price of 100% 1/0ga copper wire.
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Old 06-06-2007
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I'm mostly curious as to the lengths people used. so I know what to ask for when I get pricing.

thanks bugg for heads up on location as well.

Anyone else remember how much they used?
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Old 06-06-2007
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i got the 170 amp and i ran 1/0
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Old 06-07-2007
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When I did the Big 3 I'm pretty sure I used 14ft of 4awg.
(thats just alt to batt, batt to ground, engine to chassis.)

I guess you'll still need the starter wires.
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Old 06-07-2007
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when i put my 200amp alternator in i didnt upgrade any of the wire, is this something i should do, truck is running fine with no problems and none of the wires are hot from overheating or to much load
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Old 06-08-2007
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Quote:
Originally Posted by M50B06
when i put my 200amp alternator in i didnt upgrade any of the wire, is this something i should do, truck is running fine with no problems and none of the wires are hot from overheating or to much load
well since you didn't use any new wire you are probably only getting half of the charge from your alternator
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Old 06-10-2007
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I could sure go for a how-to on this, I only get one day off so Downtime is not an option for my truck.
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Old 09-17-2007
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Bringing back this thread. Edited first post.
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Old 09-17-2007
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you could use that wire.....it is designed for power transfer....

as far as the wire size is concerned, 4 gauge is plenty if you are running to the starter relay or battery.....you can run 4 gauge with 200A up to 9'.....and you wont need that much....

but you should also upgrade the solenoid to battery and solenoid to main fuse panel under the hood with 4 gauge wire also.....also, upgrade your battery to starter ground, and battery to chassie ground with 4 guage wire......you can go look at your truck to get an estimate of how much wire you will need......and make sure you have the proper amount of wire ends (and probably a few extra).....

when i get my new 200A alternator, i am going to use the 4 gaue i have in there now on my 125A Explorer alternator.....i have the wire oversized because i knew i was going to a bigger alternator.......
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Old 09-17-2007
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Did you run into any difficulties rerunning those existing wires?
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Old 09-17-2007
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not one.....all the stock + wires i took out. The ground wires, i left them in place and added the new wire on top of it.
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Old 09-17-2007
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Welding wire, should be plenty thick, old installers trick. also solder the ends on the wires instead of crimping. solder pellets are u friend (found em at NAPA) as is mr. propane torch.

i dont see how a "how to" is needed. buy some wire, copper ends, solder pellets and a propane torch. measure, cut, solder, seal, connect, secure, double check, drive and enjoy.

i went and made rough measurements and bought an extra 5 foot. i also counted how many copper ends i would need and bought 4 extra. same with the solder pellets and shrink wrap (actually had a **** load of ****). also got my wire from a local stereo shop. cheapest 4 awg (only did a 130A swap). the welding wire is 0 awg IIRC or thicker, hehe.

that work?
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