A little back story here.
Howard's rig has been getting harder and harder to start. One day it cranks right over, the next it lugs and starts. Something has to be up. First thing I checked for was a parasitic drain, nothing out of the norm here. I check the battery voltage and it is 11.5, a little low for the rig to just have been running. Then I remember from a few months back that Howard was saying his volt meter would only read 12 volts even when the rig was running. I fire up his rig and see that at idle its showing 12.3 volts. Hit the gas and it jumps up to 14. Agh ha............ Now I have a place to look. His rig is running the stock alternator that maybe pumps out 65 amps. With as much winching as Howard is doing lately thats not gonna cut it!!
A few phone calls and I find that rebuilding the alternator myself I can bump it up to 80-90 amps max. Thats still not gonna do it for what we do. So I do a little more thinking and remember the AC Delco CS144. It is an internally regulated alternator some GM rigs ran that cranks out 140 amps in stock form. That'll work.
Here is the old externally regulated alternator.
Side by side you can see the size difference. Another problem is the clocking of the case on the CS144. That was a simple fix. Take out the 4 main case bolts, twist to correct rotation and reinstall the bolts.
The nice thing is the mounting flanges are the same width and pattern. You just have to swap pulleys.
The wide flange on the stock alternator is a different width than the CS144, thats an easy fix though.
The stock flange was 3" and the CS144 is 2". Just make a 1" spacer to take up the space on the engine mount.
Since the case of the CS144 is larger than the stocker you have to slightly grind a corner to use the stock brackets.
I picked up a repair plug for the alternator.
The really nice thing about the internally regulated CS144 is that you only need an ignition hot wire to make it charge correctly. If you have a dummy light in the dash for the battery you should be good to go. If not you have to add a resistor in line to act as the dummy light. Here is the harness with the resistor added in line since Howard does not have a dash light. If there is a dash light its a good idea to put a resistor in parallel around it so if the light burns out the alternator will still charge correctly.
Here is the CS144 in its new home.