Alternator Replacement

I am in the beginnings of building an alternator replacement for the Nissan Xterra/Frontier V-6. I can't relocate the alternator without major surgery and I want to create a bolt-on kit. I can get a high-output, low rpm alternator that is far more common than the Nissan factory unit. What I want to know is, how many of you might be interested in something like this if I can make it work? It is looking good for the building and design process. I have already secured a machinist who will implement my design. But before I invest money and time in such a huge project, I want to make sure there is enough interest to be worth the effort. Let me know what you guys think.

Thanks for taking the initiative, but there's no way I'm spending a penny on an alternator unless it is no more costly than an original. The X alternator location is too vulnerable to justify putting an expensive unit down there.
If you can make it cheaper than the factory one, I'd condsider it, but I'd rather see a relocation project first.

Brent

Are you talking about the 130a AC/Delco unit that sells for ~$130? I was also looking into that as part of an alternator relocation kit. I believe the wiring is a little different, but it is do-able. The AC/Delco route would be significantly cheaper, as well as easier to find when you're off the beaten path. To answer your question, I woul be VERY interested in such a kit. Any idea for pricing? I would think it could be under $100 without the new alternator, as the kit will only consist of mounting hardware, hydraulic hoses/pipes, and a new wiring harness or adapter. The main cost would be in time developing it. Also, I do not see how you could perform this mod without dropping the radiator, so it may be time-intensive to install.... Just my 2c worth.

I am considering offering the kit two ways. One way would simply be an install package that would include the brackets, a pulley replacement and the wiring necessary to fit. I would base it on the GM units. On this package you could run whatever alternator you desire as long as it is the small sized one. The second option would include an alternator that produces 60% of its current at idle. As you know, the Nissan alternator produces its full current at high rpm, useless for off-roading. This package would alleviate that. But for those who want to choose what alternator they run, they could opt for package one and install whatever alternator they choose.

As for those who are complaining about the alternator location, keep in mind that this is the same location used on the V-6 Pathfinders for years. One member of my club has a 1988 Pathfinder with 200,000 plus miles on it and he has never fried the alternator in water or mud. I am not saying the location doesn't suck, it does. But, you are looking at major reworking of the motor to make it move. That is the reason Project X has a 12v air compressor as opposed to a York engine driven one. I want the kit to be bolt-on and simple enough that almost anyone can do it with regular hand tools. Relocation of the alternator doesn't fit that bill. Sorry guys, but someone else will have to slay that dragon.

Just to throw out another idea. How about putting one of those air conditioner air compressors where the current alternator is and some how move the alternator to the top of the engine.

Just a thought.

You may want to check out what Premier Power Welder has to offer before you spend a bunch of money and effort on a homemade kit. If you e-mail them, they will send you a free catalog. They told me that the Xterra has a standard small case alternator with a saddle mount. Based on what I was told, I don't think switching to a different alternator is that big of a deal. The wiring would probably be different, I'm not sure about the pulley. Their high output replacement is in the neighborhood of $300.00. I don't know what the stock alternator cost, but it wouldn't surprise me if it was as much as the Premier. I want to say the Premier was 140 amps, but I can't remember for sure.

Unless you guys come up with a better solution, I plan on buying the Premier Power Welder alternator when, and if, my stocker goes out.

Originally posted by Aussie
Just to throw out another idea. How about putting one of those air conditioner air compressors where the current alternator is and some how move the alternator to the top of the engine.

Just a thought.

The hard part is finding a place to put it (the alternator that is). The X has little room under the hood for anything. I have seen one company attach a winch motor to a York and make it work. The problem with it is size and current draw. It draws a whopping 200 plus amps. Sure it will pump up like no tomorrow, but once again, you have to figure out where to put it in an X and figure out how to mount the air tank.

As for the Nissan alternator being standard saddle mount, I am not sure until I am able to get my hands on a fried one to measure it up to standard alternators. I do know it uses an unusual pulley configuration in that it has a narrow belt with 4 ribs. Since it is non-standard, making a Power Welder fit may be interesting. But then again, the pulley may simply just transfer. It all depends on diameter and shaft size. Without a bad alternator to try it, there is no way for me to find out. I think I am going to visit a local dealer and see if I can acquire an alternator to answer my unanswered questions. After that, I will decide how to pursue a more powerful alternator.

I guess this will be a mission much like my dual batteries, on-board air and steering stabilizer. Eventually someone will figure out that it is needed and produce something. In the meantime, I will be on my own. I've done it before and can do it again.

Gordon, did you catch this post over at 4x4parts?
http://www2.4x4parts.com/cgi-local/ultimatebb.cgi?ubb=get_topic&f=5&t=000843

Brent

I would be interested in this War.

Sure the placement sucks but a better mousetrap still has a lot of merit.

Originally posted by OffroadX
Gordon, did you catch this post over at 4x4parts?
http://www2.4x4parts.com/cgi-local/ultimatebb.cgi?ubb=get_topic&f=5&t=000843

Brent

Older Pathfinders used a V-belt, not a serpentine belt. Makes it easier for pulley issues. I will keep you guys posted on my progress on acquiring an Xterra alternator. If the pulley transfer, it made save a lot of trouble in the future.

There is no way I'm going to put a costly high output altenator in the stock location. My old stang had a 130amp altenator, when it went out the only place I could find a new one was in Texas for a whopping $499.00. I was able to have a shop rebuild it for just over $100.00. Whoooo, got lucky there!!! I would be interested if an equal or greater power altenator could be put in the stock location that was cheap. My first stang, a 4-banger had an 85 amp altenator that cost about 70 bucks to replace. I'd be interested in that.

Originally posted by ScottG
Their high output replacement is in the neighborhood of $300.00. I don't know what the stock alternator cost, but it wouldn't surprise me if it was as much as the Premier. I want to say the Premier was 140 amps, but I can't remember for sure.

Unless you guys come up with a better solution, I plan on buying the Premier Power Welder alternator when, and if, my stocker goes out.

Scott,

WOW, that bugger is expensive! The 160 amp alternator lists at $799 for the saddle mount and you still have to sort out pulley and wiring issues. On top of that, It only puts out 60 of its 160 amp output at idle. Compared to the PowerMaster at $149.95 which outputs 60% at idle this is not good. My goal is to provide an alternative that can offer a better alternator at less or about the same cost as the factory one. If you plan on using the power welding side of it, I guess you could live with the high cost. But I personally wouldn't spend that much money. I think I will continue persuing the avenue I am to give people a choice. It's tough to justify that much money.

Originally posted by warmonger


Scott,

WOW, that bugger is expensive! The 160 amp alternator lists at $799 for the saddle mount and you still have to sort out pulley and wiring issues. On top of that, It only puts out 60 of its 160 amp output at idle. Compared to the PowerMaster at $149.95 which outputs 60% at idle this is not good. My goal is to provide an alternative that can offer a better alternator at less or about the same cost as the factory one. If you plan on using the power welding side of it, I guess you could live with the high cost. But I personally wouldn't spend that much money. I think I will continue persuing the avenue I am to give people a choice. It's tough to justify that much money.

The lady I spoke with at Premier a few months ago told me the alternator was $300. The entire welder setup was $799.00. I would like to get the welder after getting the alternator. It can be used as a welder, battery charger, and generator that can run power tools. The catalog they sent me even gives the part number for a craftsman air compressor that it will run. Considering all the stuff it will do, I don't think it is any more excessive than buying a winch or lift kit.

Premier lead me to believe that their alternator could simply be bolted in. The point I was trying to make above is that I don't think you need to design a kit with new brackets, etc. You just need to buy whatever brand of alternator you want that is small case with saddle mount. I would imagine that you will have to change the wire connections, and you may have to take the pulley off your old alternator.

I agree with everyone else, I would hate to spend a bunch of money on an alternator to have it ruined by mud and water. I am assuming that the stock alternator is two or three hundred bucks, so spending three hundred on the Premier when the stock alternator goes out doesn't seem like a bad choice to me. If PowerMaster has one for $150, that sounds like a good deal too. I just like having the welder option.

I'm interested. As with other people here, I wouldn't want to put a more expensive alternator in until it can be relocated, but the cheaper, more common alternator (made available by the new brackets, etc) sounds appealing.

Scott,

The positive side is that in the end, the X/Frontier owner can choose whatever alternator they want. If you want a Premier Welder, you can have it, if you want a Mean Green, the options are open, etc, etc. The two hardest parts of the kit will be machining the pulley and finding the company who can manufacture an adapter connector for the factory harness. Since I have a machinist lined up for the pulley and a contact for the connector, I think I just may be able to make this work. It really doesn't matter to me whether some choose to go another route, this is America. I just want to know if there is potential here for me to actually make this work. So far it's starting to look pretty good. The people who will be building the brackets and the pulley for me are excited to get a shot to get in the door in the Nissan market, so that in itself is a big positive sign for Nissan owners. They realize there is a hard core contingent out there and want a piece of the pie. Considering their mainstay is Jeeps, that is a good thing in my book.

Well, I just replaced my alternator... You're right- it's $275 for the part from the dealer. I wanted to keep the old alternator but he wanted $75 for it. As it was, it totalled out at $360 (part, labor and tax) I couldn't do another $75 on top of it. However, we came up with an idea for keeping crap out of the alternator, I'm gonna crawl underneath and take a look at it this weekend- in between AAL's and Bilsteins.

Ouch! $201 from nissanparts.cc...

Brent

Originally posted by Dayspring
Well, I just replaced my alternator... You're right- it's $275 for the part from the dealer. I wanted to keep the old alternator but he wanted $75 for it. As it was, it totalled out at $360 (part, labor and tax) I couldn't do another $75 on top of it. However, we came up with an idea for keeping crap out of the alternator, I'm gonna crawl underneath and take a look at it this weekend- in between AAL's and Bilsteins.

You didn't install it yourself:confused:

You should have:bloated:

Yeah, you get screwed double. One with the dealers high part price, the second when you pay to have them do the install.

Actually the X alternator isn't all that easy to swap. I pulled mine while investigating my relocation project. It's kind of a bitch to put it back between holding the damn thing up while you try and line up the bolts and getting to the terminals on the top side with the wires that aren't long enough to reach down so you can work with the terminal facing you.
Actually, I don't think I ever actually fully pulled mine come to think of it. I could see what I needed to see and didn't feel like fussing with it any more.

Brent

Sign me up for one (that welder idea would be interesting as well!):D

It wasn't supposed to cost that much. I have a friend who works at the shop where I got it worked on. He was gonna give me a break on labor. Unfortunately, one of the other mechanics did it, and billed me for the labor... However, we came up with an interesting idea for the alternator to keep crap out of it while wheeling- I'm going to look into it this weekend and see what we can do.

I would not be interested in replacing the alternator with a different one unless it is relocated. The stock location is WAY too vulnerable.