Gary's Garagemahal (the Bullnose bible)
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        • EGR System Description & Testing
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      • Tape And Decal Application
    • Fasteners & Illustrations >
      • Fastener Pictures
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      • Hood
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    • Fuel Systems >
      • 1985-1986 Fuel System Adjustments
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        • Air Cleaner Check Valves
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        • EFI Idle Speed Adjustment
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      • Fuel System Part #'s >
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    • HVAC >
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      • Factory A/C Brackets
    • Interchange >
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        • 81-06-13 Bumper Guard & Tire Carrier
        • 81-7-23 Seat Belts Become Too Tight
        • 83-3-15 Pickup Box Alignment
        • 81-06-15 Pickup Box Wood Floor Replacement
        • 83-13-4 Sheet Metal Welding Procedures
        • 83-16-17 Pickup Box Lean
        • 83-24-18 Swing-Lock Mirror Moves
        • 83-13-22 Electric Mirror Loose Glass
        • 83-24-19 Mirror Head Vibration
        • 87-01-18 Tool Box Mount
      • Electrical / Climate Control / Starting / Charging >
        • 80-4-13S A/C RAPID ON-OFF CYCLING OF COMPRESSOR CLUTCH
        • 81-1-10 FM Radio Interference
        • 81-7-24 Temperature Control Cable Too Long
        • 84-24-9 Noise - Radio Ignition Buzz
        • 87-03-07 EEC-IV Driveability TSB Summary
        • 87-07-20 Radio Ignition Noise
        • 87-21-10 EEC-IV Diagnostics
        • 88-05-07 Malfunction Indicator Light Introduction
        • 89-22-08 Emissions Maintenance Warning Module
        • 90-25-12 Speed Control
        • 96-21-04 2G Alternator Repair
      • Brakes/Steering/Suspension/Wheels >
        • 80-14-14-S STEERING
        • 81-06-04 Integral Power Steering Gear
        • 81-06-16 Front Wheel Grease Seal Gaskets
        • 81-06-17 Rear Parking Brake Cables
        • 81-2-25 REAR SUSPENSION TORQUE SPECS
        • 89-19-01 Brake Noise Recap Of TSB's
        • 89-25-16 Brake Ride Height Proportioning Valve
        • 90-13-9 Frame Cracking At Rear Shock Mount
        • 96-15-11 Frame-Rivet Replacement With Bolts
        • 97-03-10 Frame Creaking/Popping
        • Steering Gear Frame Liner
      • Engine/Cooling System/Exhaust >
        • 81-2-27 ENGINE DETONATION
        • 83-13-7 Correct Oil Fill Level
        • 83-25-21 Air Cleaner Sealing
        • 83-13-8 RTV Sealant - New Material
        • 87-06-10 Stall/No Start: TFI
        • 88-07-16 4.9L Exhaust Manifold Warping
      • Transmission/Clutch/Driveshaft/Axle >
        • 81-5-15 AOD TRANSMISSION
        • 81-06-18 Clutch Housing Fills w/Mud/Dirt
        • 81-07-25 Clutch Shudder/Chatter In Reverse
        • 81-7-26 Missing Shims On SROD
        • 82-25-16(S) Upshift Indicator Light
        • 83-3-23 Axle Lubricant Drain And Refill
        • 83-23-17 8.8" Rear Axle Vent
        • 84-24-13 Transfer Case - Grinding/Block-Out
        • 90-16-07 High Clutch Effort
      • Driveability/Fuel/Ignition/Emissions >
        • 81-6-19 Cold Driveaway Performance Improvements
        • 81-6-20 Piston Slap During Cold Driveaway
        • 81-6-21 Power Valve Vacuum Hose
        • 83-11-12-S Stall/No Start/Hessitation
        • 88-05-14 Low Oil Pressure
        • 91-25-07 IAC Bypass
        • EMW Module
      • Noise/Vibration/Ride/Squeaks/Rattles >
        • 80-1-12-S REAR SPRING SQUEAK
      • Miscellaneous/General >
        • 83-14-1 UNDERHOOD PRODUCTION STAMP RELOCATION
      • Health/Safety/Environmental Hazard information
      • CALIBRATION: 4-53F-R00
      • Fuel Cross-Flow
    • Underhood >
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      • Cooling System Illustrations
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          • Automatic Transmission Applications
          • General Automatic Transmission Service
          • Automatic Overdrive (AOD)
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          • Kickdown Linkage
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        • Manual Transmissions >
          • Manual Transmission Applications
          • General Manual Transmission Service
          • 3.03 3-Speed Toploader
          • NP435
          • Single Rail Over Drive (SROD)
          • T-18
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          • TOD
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    • Electrical >
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      • Electricity 099
      • EVTM >
        • 1981 EVTM
        • 1985 EVTM
        • 1986 EVTM
      • Gauges
      • Ground Wires >
        • Engine-to-Firewall Ground
        • Battery to Ground
        • Battery to RH Fender
        • Firewall to Hood
      • ICVR
      • Ignition
      • Lighting >
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        • Fog or Driving Lights
        • Headlight Wiring Harness
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      • PMGR Starter Wiring
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      • Windshield Wipers
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      • Wiring Diagrams
    • Emissions >
      • Inferred Mileage
      • Thermactor Systems
    • Engines >
      • Engine Building Basics
      • 3.8L (232) V6
      • 300 Six
      • Windsor Series
      • 351M and 400
      • 385 Series
      • IDI Diesel
      • Drive Belts
      • EGR Valves >
        • EGR System Description & Testing
        • EGR Spacer
        • Gasket: Carb/EGR to Intake (9447)
      • Flywheels
      • Manifolds, EGR, Heat Valves, etc
      • Engine Swaps >
        • 300 Six to Small-Block V8
      • Pulleys
      • Starters
    • Exhaust Systems
    • Exterior >
      • Beds, Tailgates, and Components
      • Bumpers
      • Exterior Mirrors
      • Exterior Trim and Moulding
      • Frames >
        • Engine Perches
      • Fuel Filler Doors
      • Name Plates
      • Push Bars
      • Spare Tire Carriers
      • Stationary Glass - Butyl Type Seal
      • Tape And Decal Application
    • Fasteners & Illustrations >
      • Fastener Pictures
      • Fenders and Aprons
      • Frame
      • Headlights and Turn Signals
      • Hood
      • Interior Trim - Bronco
      • Interior Trim - Regular Cab
      • Radiator and Grille
    • Fuel Systems >
      • 1985-1986 Fuel System Adjustments
      • 460 Fuel Systems
      • Air Cleaners >
        • Air Cleaner Check Valves
        • Air Cleaner Illustrations
        • Air Cleaner Heat Tube
        • Air Cleaner Housing #'s
        • Air Cleaner Snorkels
        • Air Cleaner Tube #'s
        • Hot Air Shroud
      • Carburetors, Chokes, & EFI >
        • EFI Idle Speed Adjustment
        • Jetting
        • How To Find Carb Parts
        • Chokes
        • Carter YFA 1bbl
        • EFI
        • Edelbrock
        • Motorcraft 2150
        • Holley 4180C
        • Motorcraft 7200 VV
      • Diagnostics
      • Fuel System Illustrations >
        • Fuel Filler Pipes
        • 1980-84 F-Series & Bronco
        • 1983-84 F-Series Diesel
        • 1983-87 F350 Chassis Cab DRW
        • 1985 F-Series 302 w/EFI
        • 1985-87 Bronco
        • 1985 on F-Series
      • Fuel System Part #'s >
        • Fuel Filler Pipes
        • Fuel Senders & Pumps
        • Fuel Tanks
        • Fuel Tank Selector Switch
        • Fuel Tank Selector Valve
        • Fuel Vapor Valve
        • Fuel Vapor Separator
      • Fuel System Wiring
    • HVAC >
      • HVAC Systems
      • 300 Six Compressor Illustrations
      • Factory A/C Brackets
    • Interchange >
      • Air Conditioning Interchange
      • Alternator Interchange
      • Brake Interchange
      • Carburetor Interchange
      • Crankshaft Interchange
      • Diesel Injector Pump Interchange
      • Distributor Interchange
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    • Interior >
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        • Vent Windows
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      • Interior Soft Trim
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      • Instrument Panel Name Plates
      • Instrument & Radio Bezels
      • Kick Panels
      • Painting Gauge Needles
      • Rear Corner Trim
      • Salvaging Rosewood
      • Seat Belts
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    • Literature >
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        • Centurion
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      • 1983 Ford Bronco 4x4 Dobbs-Stroppe Team Chase Car
      • 1983 Bronco Survivor
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      • 1985 F150 4×4 Flareside
      • Big Blackie
      • Big Blue >
        • Big Blues Documentation
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        • Air Cleaner
        • Aluminum Wheel Refinishing
        • Electrical Components >
          • Alternator
          • Battery
          • Power Distribution
        • Gauges
        • Engine
        • Frame
        • Seats
        • Transfer Case
        • Transmission
      • Rusty
    • Specifications >
      • Assembly Plants
      • Axle Ratios
      • Body Codes - Interior
      • Build Sheet Interpretation
      • Dimensions and Weights
      • Interior Paint
      • Calibration Codes
      • Certification Label
      • DSO Codes
      • Electrical
      • Engine Codes
      • Exterior Paint Codes
      • Lubricant Specifications
      • Model Codes
      • Spring Codes
      • Standard Features And Options
      • Towing
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      • Tape Stripe Codes >
        • Bronco Tape Stripe Codes
        • F-Series Tape Stripe Codes
      • VIN Decoding
    • Suspension & Steering >
      • 2WD Spindles
      • Alignment
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      • Rear Suspension >
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      • Sway Bar
    • TSB's >
      • TSB Index
      • TSB Bulletin List
      • Body/Windnoise/Water Leaks/Trim >
        • 81-06-13 Bumper Guard & Tire Carrier
        • 81-7-23 Seat Belts Become Too Tight
        • 83-3-15 Pickup Box Alignment
        • 81-06-15 Pickup Box Wood Floor Replacement
        • 83-13-4 Sheet Metal Welding Procedures
        • 83-16-17 Pickup Box Lean
        • 83-24-18 Swing-Lock Mirror Moves
        • 83-13-22 Electric Mirror Loose Glass
        • 83-24-19 Mirror Head Vibration
        • 87-01-18 Tool Box Mount
      • Electrical / Climate Control / Starting / Charging >
        • 80-4-13S A/C RAPID ON-OFF CYCLING OF COMPRESSOR CLUTCH
        • 81-1-10 FM Radio Interference
        • 81-7-24 Temperature Control Cable Too Long
        • 84-24-9 Noise - Radio Ignition Buzz
        • 87-03-07 EEC-IV Driveability TSB Summary
        • 87-07-20 Radio Ignition Noise
        • 87-21-10 EEC-IV Diagnostics
        • 88-05-07 Malfunction Indicator Light Introduction
        • 89-22-08 Emissions Maintenance Warning Module
        • 90-25-12 Speed Control
        • 96-21-04 2G Alternator Repair
      • Brakes/Steering/Suspension/Wheels >
        • 80-14-14-S STEERING
        • 81-06-04 Integral Power Steering Gear
        • 81-06-16 Front Wheel Grease Seal Gaskets
        • 81-06-17 Rear Parking Brake Cables
        • 81-2-25 REAR SUSPENSION TORQUE SPECS
        • 89-19-01 Brake Noise Recap Of TSB's
        • 89-25-16 Brake Ride Height Proportioning Valve
        • 90-13-9 Frame Cracking At Rear Shock Mount
        • 96-15-11 Frame-Rivet Replacement With Bolts
        • 97-03-10 Frame Creaking/Popping
        • Steering Gear Frame Liner
      • Engine/Cooling System/Exhaust >
        • 81-2-27 ENGINE DETONATION
        • 83-13-7 Correct Oil Fill Level
        • 83-25-21 Air Cleaner Sealing
        • 83-13-8 RTV Sealant - New Material
        • 87-06-10 Stall/No Start: TFI
        • 88-07-16 4.9L Exhaust Manifold Warping
      • Transmission/Clutch/Driveshaft/Axle >
        • 81-5-15 AOD TRANSMISSION
        • 81-06-18 Clutch Housing Fills w/Mud/Dirt
        • 81-07-25 Clutch Shudder/Chatter In Reverse
        • 81-7-26 Missing Shims On SROD
        • 82-25-16(S) Upshift Indicator Light
        • 83-3-23 Axle Lubricant Drain And Refill
        • 83-23-17 8.8" Rear Axle Vent
        • 84-24-13 Transfer Case - Grinding/Block-Out
        • 90-16-07 High Clutch Effort
      • Driveability/Fuel/Ignition/Emissions >
        • 81-6-19 Cold Driveaway Performance Improvements
        • 81-6-20 Piston Slap During Cold Driveaway
        • 81-6-21 Power Valve Vacuum Hose
        • 83-11-12-S Stall/No Start/Hessitation
        • 88-05-14 Low Oil Pressure
        • 91-25-07 IAC Bypass
        • EMW Module
      • Noise/Vibration/Ride/Squeaks/Rattles >
        • 80-1-12-S REAR SPRING SQUEAK
      • Miscellaneous/General >
        • 83-14-1 UNDERHOOD PRODUCTION STAMP RELOCATION
      • Health/Safety/Environmental Hazard information
      • CALIBRATION: 4-53F-R00
      • Fuel Cross-Flow
    • Underhood >
      • Cowl Seal
      • Engine Compartment Lamp
      • Fender Aprons
      • Speed Control
      • Tool Box
      • Vacuum Systems >
        • Vacuum Diagrams >
          • 300 Six
          • 302/5.0L
          • 351W
          • 351M/400
          • 460 V8
        • Vacuum Fittings
        • Vacuum Reservoirs
    • Metrics
    • About Me/Contact Me >
      • Youth Classes >
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          • Fall of 2015
        • Building Web Sites >
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          • Lesson 2
          • Lesson 3
          • LTC
        • Overview of Paul's Life, Journeys, & Works >
          • Lesson 1
          • Lesson 2
      • Projects >
        • Engine Cradle
        • Gauge Pocket
        • Rear Bumper And Spare Tire Carrier
    • Year-To-Year Differences >
      • Door Locks & Turn Signals
    • Test Page
    • 91-6-7 Sterling 10.25 Hub Leaks
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dad's alternator

How to rebuild a 3G alternator to 160 amp capability for installation in a Bullnose.
THE FOLLOWING HAS BEEN GLEANED FROM THE 42-PAGE THREAD CALLED DAD'S ALTERNATOR DILEMMA ON FTE.

The original alternator on the truck was what's called a 1G, meaning Ford's first generation of alternator.  And, while it was a significant advancement over a generator, it leaves a lot to be desired.  First, it puts out very little current when the engine is idling.  In fact, the headlights visibly yellow when the engine drops down to idle, indicating that the alternator isn't keeping up with the draw of the lights and the voltage is dropping.  Secondly, the alternators were only good for about 65 amps at full tilt, which was barely adequate for the truck when new, and not adequate if high-current devices like cooling fans or stereo systems are added.

Given that, I'm upgrading the alternator on Dad's truck to a 3G with a large case, and those are capable of throwing twice the current of a 1G when running at full tilt.  And, they put out several times more current at idle than a 1G, so the battery continues to be charged even idling.  However, I've done an upgrade on the large-case 3G so that it is capable of producing 160 amps.

But, let's take this a step at a time.  First things first - my friend Brandon when shopping at LKQ and came back with this haul, including an 88/89 Taurus/Sable power distribution block, another from a mid-90's Ford truck, a Mega-fuse, and a 3G alternator.
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But, that alternator needs a bit of "help" in getting ready to go into Dad's truck.  First, the bolt that pinches the adjusting arm on a 3G is metric, but the one in the truck is SAE.  So, I tapped the ear on the case 3/8-16:
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Then, the original adjusting arm has a bend in it that causes it to hit the 3G alternator:
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Here is the bend that causes the problem:
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And, here's how I flattened it:
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Then, I ordered the following from National Quick Start:  (NB: I'm not suggesting you buy from NQS as I had several problems with my order.  But, at least knowing where the parts came from you can figure out what they are from their web site.)
  • Rectifier bridge: # 502073 - 200A
  • Slip ring: # 282855
  • Brush Holder: # 39207
  • Rear Bearing: # 610084
  • Front Bearing: # 63034N - NTN
  • Regulator: # F794HD
  • Pulley: # 242105 - 2 groove 10/13 mm

​Why the pulley?  Along the way in researching alternators I discovered that it is difficult for one vee belt to provide more power than the equivalent of 95 amps.  So, my plans are to use two belts.  However, it turned out to be a bit more difficult than just ordering in that 2-groove pulley from National Quick Start.  First, I discovered that the front two sheaves on the standard crank pulley for an M/400 are different diameters.  Obviously that won't work, so a friend in Florida (thanks, Shaun) found a small-block Ford pulley that has the front two sheaves the same diameter.  Then I realized that the front belt on the truck's accessories as well as the crank pulley is 13mm wide and the second belt is 10mm wide, but the original alternator pulley had two 10mm sheaves so it wouldn't take the front belt.  Not to fear, NQS said they had a two-sheave pulley that would work.  Unfortunately, when I got the pulley in I discovered that the width of the sheaves is backwards.  In other words, the front sheave was 10mm and the second sheave 13mm wide - and they didn't have the right pulley.

​So, I put the original pulley, bottom, against the NQS pulley, on top:
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​Hmmm, if some of that meat were taken out of the middle of the original pulley.....
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​Then, I did a bit of powder coating on the alternator's case halves as well as the pulley:
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