Updating my Alternator to a CS-144

[DieselCash]

This thread will be continuously updated over the weekend till I get everything completed. I will start with this picture:


That is a brand new CS-144 Alternator with a life time warranty. I only paid $162 for it including the $5 core and tax. That is also with my 10% military discount. :thumbsup:

I will take tons of pictures with a step by step how to for everybody to follow and hopefully help fellow TTS members.

I will start this out with what I currently have and the problems I am having.

 

[DieselCash]

Here is my old alternator, it is a fairly new Bosch unit:


The brackets on the old and new will be a little different:


The wire connector is the same on the old and new:


Pictures of the new Alternator will be next! :thumbsup:

 

[DieselCash]

Here is the new Alternator. It appears to be a lot bigger and seems heavier than the one in my truck currently. If you notice the plug is the same on both. The stud for the power output is bigger on the new one. I will show this later, here are some pics:

 

[DieselCash]

My current gauge from in the inside of the cab:



It has not been to 14V in over 2 weeks. I tested it over three weeks ago and it was at 14V at the time. But it always drops low when I have anything turned on. The last time I tested it it dropped to 13.2V with the headlights on, A/C on high, and the blinker on. It has gotten a lot worst over the last two weeks.

The batteries are only about 6 months old. The current alternator was on the truck when I purchased it. I have no idea how old it actually is.

I already pulled and cleaned the ground on the front passenger side frame. It helped for a day or two. Mine runs a little different. It goes from the frame to the fire wall with one ground strap. Then from the fire wall to the engine on the back of the passenger side head on a different ground strap.

The way I see it any vehicle with two batteries should never have a 95 amp alternator.

I will try to rip it all apart tonight. :thumbsup:

 

[DieselCash]

Alright, I got the old alternator out. Here is how I did it. First thing I did was disconnect the grounds on both batteries. Here is a picture of all the tools I used:

Then I pulled the belt of the alternator.

I then used a 10MM socket to disconnect the power stud on the back of the alternator. While I was there I used a flat tip screwdriver to remove the plug.

With the belt and power out of the way I went to remove the alternator. Mine is held in place with three bolts. Two 1/2 inch bolts on top and one 15MM bolt with a 15MM nut on the bottom.

Here is what she looks like with the alternator out of the way.

 

[great white]

Question;

Since the tachometer uses the alternator for it's signal, will this affect it's operation?

:scratchhead:

 

[DieselCash]

Question;

Since the tachometer uses the alternator for it's signal, will this affect it's operation?

:scratchhead:

I have no clue on that one, I will leave that answer for the experts on this site.

 

[handcannon]

Question;

Since the tachometer uses the alternator for it's signal, will this affect it's operation?

:scratchhead:

I don't think so.

I now have a CS144 alt. It still has the incorrect size pulley as I don't have a box wrench that goes deep enough into the pulley to grip the nut. When I got the truck the original alt had been replaced and had the wrong size pulley. Now, the CS144 with the incorrect size pulley shows the same RPM as the original alt did with the incorrect size pulley.

I've been slacking on getting the pulley swapped for the correct one because I primarily use the Tiny Tach to watch engine RPMs.

Don

ps--I guess I'm going to have to get off my duff and get that pulley swapped so I know for sure what the answer to your question is BJ. Tomorrow I'll try again to get a wrench in there to remove the pulley.

 

[THEFERMANATOR]

Question;

Since the tachometer uses the alternator for it's signal, will this affect it's operation?

:scratchhead:

No, it won't change anything. Both alternators use a diode trio, so both put out 3 pulses every alternator revolution. And for those of you with a 96+ truck, use an alternator for an 01 DMAX as it will have the correct size pulley and is a drop in replacement.

 

[great white]

No, it won't change anything. Both alternators use a diode trio, so both put out 3 pulses every alternator revolution. And for those of you with a 96+ truck, use an alternator for an 01 DMAX as it will have the correct size pulley and is a drop in replacement.

Now that's some good info!

:thumbsup:

 

[DieselCash]

I got it installed! :thumbsup:

It will hold 14v with everything turned on, when before with everything on it would drop to 13.1V.

Here is pictures of a comparison side by side:

For some reason I can not post any pictures onto the site! :mad2:

The power stud on the back of the CS-144 is at least twice the size of the CS-130. The 130 had a nut size of 10MM and the 144 had a nut size of 1/2inch. You can see the difference in the above pictures.

 

[DieselCash]

To install the CS-144 I had to remove the large bracket.

I then removed the small bracket pictured above of the back of the belt tension er and flipped the bracket. The alternator side of the small bracket had to have the hole enlarged for the bolt. I also had to purchase a 3/8" X 4" bolt, nut and lots of washers. I needed 1" spacer but could not find anything in the correct size so I used 1" worth of washers. The wife put me on a timer for this! :mad2: She had plans! :mad2:

Here is what the backside looks like installed:

Looks good and holds in place nicely only having two brackets holding her in.

Know I just need to find or make a spacer and a rear bracket.

 

[colbythekid]

Know I just need to find or make a spacer and a rear bracket.

Are you running the truck with just the two bolts in the alternator right now? I had mine installed the same way, but did not want one of the bolts to give out and blow up the radiator with a flying alternator. Nice write up by the way! Looks great and love all the pictures!!

Colby

 

[DieselSlug]

I also have a cs-144 alt sitting on the bench waiting for me to install it. Im reading about 11-12 volts on my meter....

 

[Burning oil]

I've had some parts for a few days that I want to mock up the rear bracket with.
I would highly recomend you add a rear bracket. I installed a new alt on my 93 a few years ago. The rear bolt had worked itself out and one day I was ideling at a customers, next thing I felt was the whole truck shook. I tought someone had bumped my bumper?? anyway it turned out the new alt ripped itself right of the truck. It broke the big support boss on alt in half and the alt was just danggling there.
Moral= support the alt at any/every place you can.

 

[WarWagon]

Looks like you got a busted a fin on the cooling fan of the CS144.

X2 on the rear bracket - it keeps the alt straight so it doesn't throw the belt. Diesels are known to break the alternator brackets so any rear bracket has to be extra tough.

 

[DieselCash]

I've had some parts for a few days that I want to mock up the rear bracket with.
I would highly recomend you add a rear bracket. I installed a new alt on my 93 a few years ago. The rear bolt had worked itself out and one day I was ideling at a customers, next thing I felt was the whole truck shook. I tought someone had bumped my bumper?? anyway it turned out the new alt ripped itself right of the truck. It broke the big support boss on alt in half and the alt was just danggling there.
Moral= support the alt at any/every place you can.

When you mock it up take some pictures and post some details. I can use all the ideas I can get. :thumbsup:

 

[DieselCash]

Looks like you got a busted a fin on the cooling fan of the CS144.

X2 on the rear bracket - it keeps the alt straight so it doesn't throw the belt. Diesels are known to break the alternator brackets so any rear bracket has to be extra tough.

Thanks for pointing that out! :thumbsup:

Got to love lifetime warranties! :hihi:

Hopefully soon I can mock something up for the rear of the CS-144.

 

[Burning oil]

My first idea was to try a turnbuckle arrangement. I have a couple to try, but I think a 1/4 or 3/8" bar would do real well. Just have to have my metal shop guys program it and plasma cut a few out.

 

[THEFERMANATOR]

I took my stock rear bracket and cut it off to clear the alternator, and welded on a piece of 1 inch angle iron to it and bolted that to the rear of the alternator when I did mine. I also used a piece of 1 inch wide flat plate for teh upper mount to make it more stable as the reversed bracket set-up had to much flex for my taste when I did mine.

Heres the pics I had over at DP from when I did mine. Worked fine with a stock belt. I may even still have them out in the shop if anybody is interested.