Delco 94 Amp Alternator installed
Delco Alternator Swap
The trusty 87 Range Rover has only left me stranded on two
occasions, and both times it was a dead alternator that brought the "Best 4
by 4 by far" to a halt by the side of the trail. More specifically, it was
a dead diode in the alternator and then a dead battery. Judging from all of the
questions on replacements this is not an uncommon Rover malady, especially as
machinery reaches the 100,000 mile mark.
The simplest solution is as close as your local Rover dealer
or parts supplier. They can supply you a replacement Lucas for under $250 or so.
Installation only takes a few minutes, and you are on your way, probably with a
warranty. This may just be the most cost / labor effective solution, especially
if you'll be selling the Rover in the next few years.
However, what if you aren't planning on selling off your
friend so soon, and what if you can't always be within driving distance of a
Rover-savy supplier when the juice stops flowing? Wouldn't it have been nice if
it just took a basic Delco alternator? Virtually any parts store from Anchorage
to LaPaz could solve the problem. Hmmmmm.
Now, those that know me know how much I like to keep things
stock and simple, but this swap was just too tempting to pass up. The Series,
motorhome, and boat already have similar Delco units, why not the Rangie too?
Just to keep things simple I had standardized on the same one as is used in a
motorhome, model 7294, available at many auto parts stores. It's spec'd at 94a output which is slightly
above the rating of the Lucas unit, and at under $100 the price wasn't all that
bad either.
Click on images to view full-size
One major question was the tachometer hook-up. It would be
kind'a nice to keep that. Surprise! Seems that some Delco's have an
additional terminal, and upon opening and comparing the Delco and Lucas I could
see that it was attached in the same place that the Lucas used for the tach
hook-up. Part number they supplied it under is 7294. This was just too easy, and what do you know, it worked! I checked
around, and after opening numerous boxes from several different places that
supplied that alternator I found that most had the tach output. Click on the above photo and you'll
see where the output is located. Double check before you buy though just
to be sure - if you want the tach hook-up.
All that's needed to do the swap is a simple bracket to adapt
the Delco to the different style Lucas mounts, and a modification of the top
bracket to accommodate the different angle of the Delco. All-told, it was about
a 6 hour job to get everything changed over. As for the bracket details, well,
as they say, a picture is worth 1000 words, so see the accompanying photos for
details.
A couple important notes:
1.Because the Delco pulley diameter is slightly different, the
tach reads a bit low. Not a big deal, especially with the automatic transmission
deciding shift points for you. If you want to get it to read correctly almost any
speed-shop carries Delco alternator pulleys in a variety of sizes.
2. If for some reason you take the alternator apart, when you
put it back together it can be a real job getting it assembled with the spring
loaded brushes in place. If you look on the outside by the brushes, there is a
little hole. This allows you to install the brushes and insert a piece of stiff
wire to hold everything in place while you put the case halves back together.
Withdraw the wire and the brushes snap in place. Neat! However, be warned too
that in most cases your warranty is void if the cases are split. In many cases
there is a little tell-tale tag installed. I guess this means to be extra
careful.
3. Use at least grade 5, or even better, grade 8 bolts for
attaching things.
4. The wiring shown is for the 87 Range Rover. Other models
may differ, so consult the wiring diagram in your owners manual to be sure.
5. Finally, and most important: You have to judge your own
capabilities and determine if you have the appropriate experience and are
capable of performing these modifications which include cutting, welding, and
electrical work. This modification may void other warranties, so be sure to
check first. For safety, be sure to always disconnect the battery before working
on the vehicle.
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