Alternator Upgrade Guide for RB30 Patrol

[dom14]

Hi Guys,
This is a write up on alternator upgrade for the RB30 Patrol.
This upgrades the stock 60A alternator to 110A for around $50 or less.

Stuff
1)Alternator from EF-EL Falcon(Make sure to grab a one with no transmission oil baths or damage. Also ensure to get a one with the EF Falcon serpentine pulley. The pulley itself is no use, but you need a part from it to make a pulley shim)
2)About a meter of 100A+ capable wire(Autobarn, Jaycar electronics, etc)
3)100A+ inline fuse holder with fuse.
4)Couple of matching lugs (to connect the alternator charge wire to the alternator & battery)
5)Few large nuts & washers (to use as spacers for the alternator top & bottom mounts to align the alternator with the water pump pulley & crank pulley).
6)About a meter of matching wire conduit for the new alternator charge wire.(from Jaycar Electronics, ebay, etc)


Tools
Angle grinder
Hand file
Hacksaw
Bench vice


This is by no means a one hour job that you can use EF-EL Falcon alternator to quickly replace the stock alternator. A bit of "panel beating" is required, as well as bit of extra wiring(A new charge wire to match the high amp alternator).

Note: Some of the pictures with detailed measurements are added as a guide only. You don't need to be exact like a machinist. I added those pictures for any future reference, for any other projects, etc.

P.S. Special Thanx to the forum member "Throbbinhood" for introducing me to this modification.

[dom14]

Here's the photo bombing with details embedded.

Note: Some of the detailed measurements are an overkill. I took them during the job just in case. They can be useful for other projects in the future, either for me or anybody.

[dom14]

Second lot of photos

[dom14]

More photos

[dom14]

This is what i had to go through after buying the EF Falcon alternator without knowing too much about the details of the transmission oil damage that some of them come with.

I had to spend two days, first pulling it apart and cleaning it, then rebuilding it with new bearings, then putting it back together. All of that was not necessary if I cared enough to buy a good used one.

Here are the photos of my nightmare.

These three photos show what the alternator look like when I pull it apart.

[dom14]

These are the photos after full rebuild of the alternator. It wasn't worth my money or my time.

But, I learnt a valuable lesson about my stupidity of not checking things properly while I am half asleep.

[dom14]

Yo Craig, I just sent you an abusive PM for not thanking the last set of photos.
Here you've done it. :D
I'm gonna have to write you another one with an apology.
Cheers
Dom :D

[Throbbinhood]

Great write up Dom. Handy mod too for anyone thinking about it. EF/EL alternators are everywhere and cheap. Made a big difference to my rig when winching, plus the batteries recover quicker after winching or a discharge after a few nights at camp. Plus, I can have all the lights on with no dimming at idle, even with all the other electrics on, bonus!

[dom14]

Great write up Dom. Handy mod too for anyone thinking about it. EF/EL alternators are everywhere and cheap. Made a big difference to my rig when winching, plus the batteries recover quicker after winching or a discharge after a few nights at camp. Plus, I can have all the lights on with no dimming at idle, even with all the other electrics on, bonus!

Yeah, I'm really happy with the mod. I spent too much time on it because I wasn't careful enough to buy an alternator without any dramas.
BTW, thanks for introducing me to this mod.
One of the addedl advantages for me with this moded alternator is that it tend to recharge the battery quicker on short everyday errands.