Alternator upgrade for 2005 Ford E-350 with gas V10 engine?

[geoffff]

Hi, I've been scouring the forums here and the internet for ideas to upgrade my stock 130A alternator to something a bit larger, like a 200A alternator. I want something reliable. I'd prefer to avoid the complication of dual alternators.

Anyone here have a 2005 V10 who has upgraded their alternator and is happy?



I've looked at these websites that come up frequently:

Tucson: Lists a lot of options for the 2005 gas v10. These all have the 3G connector. Should I still need the 3G connector not the 6G?
Nations Starter: Only option seems to be Penntex PX-5R, but I read Penntex requires an external regulator (which I don't have).
DC Power: Doesn't list the gas v10 engine for 2005 E-Series
Mechman: Doesn't list the gas v10 engine for 2005 E-Series

 

[kbeefy]

I just picked up a 250A alternator from Tuscon (in Pheonix). It comes with the adapter pigtail for the harness.
Seems to be working fine.

I also recently got a 270A alternator from Singer Alternators. Seems like a nice unit.

Singer Alternators | For all your high output alternator needs

Singer Alternators offers a premier OEM grade alternator for any vehicle type. Tested in the worst conditions, Singer Alternators can't be beat!

www.singeralternators.com

Heres the price list from Singer for my 6.0. I assume it would be similar for your 6.8.

MDL PRICE IDLE OUTPUT
200A $469 170+A (220A peak)
220A $489 175+A (240A peak)
250A $529 190+A (270A peak)
270A $549 200+A (280A peak)
290A $599 240+A (315A peak) power edge version (best idle)
320A $629 205+A (345A peak)
350A $649 210+A (365A peak)
370A $669 220+A (380A peak)
390A $699 225+A (400A peak)

 

[posplayr]

I have ordered two of these. One for a 2002 e-250 5.4l and a 2000 e-350 6.8L v10.

In the e-250 will deliver close to 100 amps at idle above s beyond the standard loads

300 Amp Heavy Duty High Output NEW Alternator For Ford E350 Super Duty E150 | eBay

100% New Premium Quality 300 Amp Alternator. Will Replace Factory 3G Series Alternator Only. This Is Truly A High Amp Premium Quality Well Built Alternator. ( Compare the pictures with the original alternator).

www.ebay.com

 

[N147JK]

I wanted to make my alternator as reliable as I could, given the vehicle's "mission". There is so much cheap aftermarket stuff out there these days, I decided to overhaul my alternator myself. There are several companies that sell overhaul kits, and some include the ability to increase amperage at the same time. Here is one example.. Home - Alternator Starter Rebuild Kits

 

[vandiesel]

Geoff, I put in a leece neville ambulance alternator that puts out 270 amps I believe. I had a DC power 270 that was not working at the time and needed it fixed fast and the leece was able to be delivered in time. I had a 6.0 and I know that the V10 is different. I bring it up because DC power re-cased my unit to fit the godzilla. If leece neville would do the same I have an amazing unit sitting on a shelf with hardly any time on it. Might be worth a look.

 

[geoffff]

kbeefyt -- thanks, I'll send an inquiry to Singer

N147JK -- exactly! I'll happily spend more for something that won't let me down when I'm far from pavement. I'm not sure I trust myself to rebuild an alternator, though

posplayr -- That's pretty cheap! But I don't think I'm comfortable installing a no-name alternator from ebay.

vandiesel -- thanks, I can contact DC Power to ask about recasing something even if they don't list any alternators for my application, but this customization makes me a bit uneasy.

 

[geoffff]

Mostly, I'd just like a mild upgrade in amps with something that has a proven track record of reliability.

 

[posplayr]

posplayr -- That's pretty cheap! But I don't think I'm comfortable installing a no-name alternator from ebay.

This is the only one I could find that claims to have advanced protections. In other words, it will back off charging for either current limiting or thermal limiting. And it does look good.

"This Is Truly A High Amp Premium Quality Well Built Alternator
It Has OE compliant functions : current limiting, thermal shutdown,
load dump protection, shorted field & lamp circuit protection "
The 2002 E-250 has an 12V rooftop ac connected to 300 Amp-hr of AGM (not counting the start battery). The alternator his directly connected to the 12V Air/AGM pair. It will idle pushing 70 amps to the AGM batteries (depending on charge) and slowly drop to 14.0v at the alternator idling after about 5 minutes. With 6 AWG 10 ft wires I have about 13.6V across the AGM's which does not cause a low voltage fault on the 12v invertor AC.

You would need more than a 60 Amp DC-DC to deliver this same amount of current. I'm using a Victron for AGM smart battery relay. A Renogy 40 Amp DC to DC charger would drop too much voltage and cause a low voltage error on the AC unit.

On startup I have see more than 100+ amps delivered (the 100 amp hall effect amp meter maxes at 100 A). My point is, I'm stressing the alternator more than any standard DC-DC charger (you would need at least 60 amp unit) and the alternator is unphased. Chassis loads are in addition.

Amazon.com

 

[arctictraveller]

I just picked up a 250A alternator from Tuscon (in Pheonix). It comes with the adapter pigtail for the harness.
Seems to be working fine.

I also recently got a 270A alternator from Singer Alternators. Seems like a nice unit.

Singer Alternators | For all your high output alternator needs

Singer Alternators offers a premier OEM grade alternator for any vehicle type. Tested in the worst conditions, Singer Alternators can't be beat!

www.singeralternators.com

View attachment 978655

Heres the price list from Singer for my 6.0. I assume it would be similar for your 6.8.

MDL PRICE IDLE OUTPUT
200A $469 170+A (220A peak)
220A $489 175+A (240A peak)
250A $529 190+A (270A peak)
270A $549 200+A (280A peak)
290A $599 240+A (315A peak) power edge version (best idle)
320A $629 205+A (345A peak)
350A $649 210+A (365A peak)
370A $669 220+A (380A peak)
390A $699 225+A (400A peak)

 

[arctictraveller]

I installed a 250 amp alternator from Tucson alternator exchange. The first one they shipped I didn’t notice it had the wrong pulley, and it ended up slicing a section of the $80 belt off. They sent me a replacement and when I received it I noticed it only had two mounting bolts, with no provision for the stock Ford third mounting bolt that uses a bracket on top. I questioned them about that, and they said They don’t offer one utilizing three bolts But they’ve never had a problem. Fast forward five months, and the two mounting bolts both broke after an extended period of time at high rpm’s while climbing a steep mountain pass. This caused the alternator to fall off and spit the belt. After a $400 tow I was able to remove the two broken bolts from the manifold, and find two used mounting bolts to hopefully hold the alternator in place until I can replace it with one utilizing three bolts.

 

[geoffff]

arctictraveller> That's terrible! I'll make sure mine has all 3 bolts!

kbeefy > Singer sent me the exact same list when I asked about my gas V10 engine. Hmmm... that's weird. I will have to call them to make sure the number of bolts is right.

 

[kbeefy]

arctictraveller> That's terrible! I'll make sure mine has all 3 bolts!

kbeefy > Singer sent me the exact same list when I asked about my gas V10 engine. Hmmm... that's weird. I will have to call them to make sure the number of bolts is right.

Mine has 3 bolts, I don't remember what the mounting differences are for the v10.
I think I may have seen the oversize cases use fewer bolts for fitment.

 

[kbeefy]

Does the v10 have 2 bolts underneath going aft and one at the back going forward?
Totally different mounting from the diesel.

 

[doublevan2]

Hi Jeff -- if possible can you supply me with the parts/data/model alternator you got from Singer ? I'm thinking of going that route of increasing alternator size on my 2002 V10 E350 also. Appreciate it - thinking on pulling the trigger sometime late April or early May.

 

[geoffff]

Michael Singer sent me the exact same text about alternators for my V10 as kbeefy received for his 6.0 diesel. I will try to call tomorrow to verify this is correct, and number of bolts

I offer any of these options to replace the factory location.

138.5MM denso hairpin style (6 phase)

MDL PRICE IDLE OUTPUT
200A $469 170+A (220A peak)
220A $489 175+A (240A peak)
250A $569 190+A (270A peak)
270A $589 200+A (280A peak)
290A $609 240+A (315A peak) power edge version (best idle)
320A $629 205+A (345A peak)
350A $649 210+A (365A peak)
370A $669 220+A (380A peak)
390A $699 225+A (400A peak)

 

[arctictraveller]

Hi Jeff -- if possible can you supply me with the parts/data/model alternator you got from Singer ? I'm thinking of going that route of increasing alternator size on my 2002 V10 E350 also. Appreciate it - thinking on pulling the trigger sometime late April or early May.

I got it at Tucson alternator exchange but I’m on a trip and don’t know the model number but they told me all the high output models they sell only use the two bolts. It’s a 250A likely due to fitment issues with the large case.

 

[doublevan2]

Thanks for taking time to respond Jeff - travel safe and have bucco fun !

 

[moorefc]

Here is a place to explore. Great source.... I've used them for parts and advice for alternator reliability...
Once rebuilt my stock 130 to 200+ by replacing (blown) diode bridge and rectifier/voltage regulator with higher rated components...
He has been in this specialty for a long time:
Go to the site map and wander around....

Ford type 3G Series High Output Alternators

High output 3G series alternators to upgrade your '96 to '99 Ford vehicle.

alternatorparts.com

National Quick Start Sales, High output alternator, Alternator & Starter Parts

Click on Alternator Series listed below for more details If you are not sure what series alternator your vehicles has CALL 616-785-7990

store.alternatorparts.com

 

[geoffff]

Here is a place to explore. Great source.... I've used them for parts and advice for alternator reliability...
Once rebuilt my stock 130 to 200+ by replacing (blown) diode bridge and rectifier/voltage regulator with higher rated components...

Thanks!! This Quick Start place looks real good. It definitely makes me feel more confident to work with a place that explains things, so I can understand why I'm paying the extra money.

Some key info:

• My van still uses the 3G alternator. Ford still used these old 3G alternators in the E-Series vans up through 2010.
• They list a 200A model selling for $360 that sounds about right for me
• They sell optional add-on external rectifiers (mandatory for >200A) that I don't think I need this for my application, as I'm just trying to get a few more amps at idle.