Renix XJ alternator relocation and upgrade

Mounting a 136 Amp alternator where the AC compressor used to be on my Renix Jeep XJ.

Since I don’t have AC on my off road Jeep, I decided to try to relocate the alternator to the area normally used by the compressor. I looked into making brackets, but I found they were readily available on Ebay.

When I got the kit, however, I found it will not work with the Renix style compressor bracket. It needs the HO style with the bolts going down into the bracket. Since I had one of those on the parts Jeep, I swapped that out.

Next I discovered that the bracket will not work with the Renix alternator. The mounting tabs are different. So I used the alternator from the donor Jeep as well. It was a bit stiff to turn at first but it freed up and seemed OK.

I measured for the belt and found it was between 77 and 78 inches so I got both belts at the parts store. Either seems to work. The 77 inch belt is part number 770K6 and the 78 is 780K6. I did not check to see if they had a 775K6 in stock. https://amzn.to/32VhD93

The later alternator uses a different control scheme than the Renix so I had to get an external voltage regulator. I used this one: https://store.alternatorparts.com/hd-external-voltage-regulator-conversion-kit.aspx

I used a larger black wire for the ground than what was supplied since I already had a wire with a loop end on it on the shelf. I cut the yellow wire on the old alternator plug and connected it to the short red wire on the voltage regulator. I used the supplied loop ends and put them on the red and black wires. I then connected them to the field terminal wires that are held in place by 7mm nuts. I ran the ground from one of the posts on the alternator to one of the mounting screws on the voltage regulator. I connected the oud red output wire to the output post just like the previous set up.

When I started up the engine, the voltage read 15 volts. This was too high for me. The voltage regulator has an adjustment pot on the back, so I had to unbolt the box from the firewall to adjust it. Note that the unit must be grounded to work. So, I used vise grips to connect the ground wire to the case while I made adjustments. I eventually dialed it in to 13.7 volts. Once it was set, I reattached it to the firewall.

I ran it for a few minutes and then I noticed that the old alternator from the donor was smoking slightly and making noise. I guess the old bearings were rusted some. Rather than mess with swapping bearings, I decided to upgrade the alternator to the Dodge unit rated at 136 amps.

I ordered this: https://amzn.to/2O2cNCR. The case is just slightly bigger and I had to grind on the mounting brackets just a little to get it to fit. I used modeling clay between the alternator and the bracket to see where it was hitting and after a few attempts the larger alternator dropped right in place.

The wires hooked up exactly the same as the Jeep alternator. Upon starting the Voltage read 13.8V so no adjustments were needed to the Voltage regulator.

This mod not only gets the alternator up out of the mud but the Dodge unit gives a few more amps as well. I think the original alternator was less than 100 amps so this will be a nice upgrade in winch spinning power.