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Old 03-23-2011, 09:39 AM
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Join Date: Jan 2001
Location: Alexandria, Virginia
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Originally Posted by dudemanstan View Post
i did the swap when i had my '80 300TD (n/a), fit fine. you may need to change belt size due to slightly different positioning, but thats about it iirc. i used two 8ga wires i think, wired straight to the battery.
I got lucky with the belt. Despite the larger alernator, it was just long enough to fit without being too tight. To keep the upgrade simple and less obvious, I ran the heavy cable direct to the starter. I also needed to rotate the 'clock-position' on the case to better position the terminals. Still need to make an insulated clip to secure the cable at the intake brace, and keep it from drifting too close to the exhaust.

The big challenge was removing the old alternator, as the bottom bolt was rust-welded into the aluminum bracket. Figure it took at least an additional two hours removing the old alternator with the bracket, then alernately working the bolt back & forth with a breaker-bar and impact-gun, along wiih heavy doses of oil, until it finally came free. I really dreaded the idea that I would've had to drill that long bolt if it had snapped!

Decision remains on whether to make a small bracket to secure the original harness at the alternator and keep the short jumper-wire I made for the charge-lamp, or cable--tie the harness at the inner-fender and run a longer wire.

Happy Motoring, Mark
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