Crown Vic Police Interceptor 215amp alternator

702GT

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There's been some hit and miss threads on alternators and what works, what doesnt, and what's shitty. Since my factory OEM alternator first took a dump at 25k/mi and was replaced with an OEM reman unit, I have been plagued with electrical trolls. Wierd things pop up here and there, funky readings (at one point my livewire recorded 15.5v steady, a few months later 12.5v, last month 14.5v), and the flickering headlights. It is no secret the 6g alternators are piles of dog heave. People have also upgraded to the PA alternators and that seems random at best as to whether it is an upgrade or will fail inside a year. There are other prospects worthy of note, such as the Denso line of performance alternators (even the OEM 2010 alternator) and Mr. Amp, ect.

For me, I feel the police interceptor 215amp alternator never got enough discussion. For the price ($130 after core return for me) ranging from $100-$200 it is possibly the best bang for your buck. Good luck with part numbers, my NAPA receipt says #213-8483 but doesnt yield results on their website. When i ordered at the counter, we looked up a 2008 crown vic police interceptor package, which listed 3 alternators. A 135amp, 190amp, and 215amp. I ordered the 215, though its far more than I will ever need.

It should be noted that the police interceptor alternator is slightly longer than the OEM Mustang 6g, not sure if a PD blown application will clear, depending on placement. Also the 3-wire connection and output stud are in different positions, as seen in the pics. It is neccessary to remove the output stud extension, as even when modified and clocked, will not clear the bottom of the intake manifold on the mustang. You will want some nylon spacers/washers to put between the casing and cable. I also re-used the nut off my OEM stud as it has a floating washer attatched.

I did not upgrade the alternator wire currently, I just needed to get that raggedy POS 6g off my car while I wait on plates for my truck. I do plan on upgrading to a #4 residential wire. I run all my automotive power wires in residential grade wire. They are more compact and capable of carrying higher amps/volts at continuous power without worrying about heating the wires. They can be more difficult to work with because of the thicker individual wire strands make them stiff. Whatever you choose to use, make sure you upgrade that alternator cable, as it is not rated for 215 amps, and if you run heavy electronics, the alternator will try to push it.

I will add to this thread and update as I go.

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JUSTA3V

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I'm running that same alternator. Been in for 2 years now. I never thought of upgrading the wire.

I better go take a look at stuff.

Thanks for sharing that.
 

Department Of Boost

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I've tried to get these to fit on a few PD cars and they didn't. So I kinda gave up on them.

When I went 200+ amps I talked with a bunch of people who should know what to run for cable. All of them said go 2ga. So now I run 2ga alternator and ground wires.
 

07BLACKStang

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I've tried to get these to fit on a few PD cars and they didn't. So I kinda gave up on them.

When I went 200+ amps I talked with a bunch of people who should know what to run for cable. All of them said go 2ga. So now I run 2ga alternator and ground wires.

Did you happen to try on your KB? I have a KB 2.6. If this won't work, I found a good deal on a PA 130amp.

What would cause you to need the 200amp anyway? Sorry if that is a noob question. I don't run much over stock as far as electronics. I have gauges, intercooler pump and an aftermarket head unit. Would I benefit from a 200amp?
 

JUSTA3V

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I installed mine because I was chasing down a dying battery issue after I relocated it to the trunk. Turned out to be a ground issue. I don't think its needed in my application, but its on the car and working fine so it can stay there.
 

702GT

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I've tried to get these to fit on a few PD cars and they didn't. So I kinda gave up on them.

When I went 200+ amps I talked with a bunch of people who should know what to run for cable. All of them said go 2ga. So now I run 2ga alternator and ground wires.

This is why i went residential grade wire instead of automotive/audio grade. I use 2x #4 wires for my battery relocate in the trunk. A single #4 is capable of 100A continuous at 110v. At 12v it is considerably higher. The amp draw for a starter is massive! (Obviously limited by the battery, in such case around 550-700 cranking amps). No one big deals it since this amp load is momentary (1-3 seconds to start a car). But it makes me feel better. The next best thing for a battery relocate is welding cable 1/0 or 2/0 and that is expensive heavy shit. I use a 1/0 for battery ground. A single #4 at the alternator casing to chassis ground. I would like to join those grounds as well, just havent gotten to it yet.
 

702GT

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Did you happen to try on your KB? I have a KB 2.6. If this won't work, I found a good deal on a PA 130amp.

What would cause you to need the 200amp anyway? Sorry if that is a noob question. I don't run much over stock as far as electronics. I have gauges, intercooler pump and an aftermarket head unit. Would I benefit from a 200amp?

Heat. All these numbers are thrown out under peak efficiency. The hotter wire and alternator get, the less produced and more lost. A 130a alternator may put out 85-95a at its best rpm but worst heat efficiency range, possibly more/less. A 200a alternator is going to idle at that (hence the use in police cars, where heavy power draws are in use but they sit and idle alot).
 

702GT

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I'm running that same alternator. Been in for 2 years now. I never thought of upgrading the wire.

I better go take a look at stuff.

Thanks for sharing that.

You can probably keep getting away with it. But if the battery dies and the alternator goes WOT to try and charge it, you could have a bad day. That cable won't hold a max charge load for an extended period above 100A. I'm not worried about it in the short term, but it needs to be done, for in the case mentioned.
 

Pentalab

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This is why i went residential grade wire instead of automotive/audio grade. I use 2x #4 wires for my battery relocate in the trunk. A single #4 is capable of 100A continuous at 110v. At 12v it is considerably higher. The amp draw for a starter is massive! (Obviously limited by the battery, in such case around 550-700 cranking amps). No one big deals it since this amp load is momentary (1-3 seconds to start a car). But it makes me feel better. The next best thing for a battery relocate is welding cable 1/0 or 2/0 and that is expensive heavy shit. I use a 1/0 for battery ground. A single #4 at the alternator casing to chassis ground. I would like to join those grounds as well, just haven't gotten to it yet.

Per the wire tables, 4 ga is good for 88 A continuous. 2 in parallel is good for 176A continuous.

3 ga is good for 100 A continuous.

Ac or dc doesn't change the ampacity of any wire. House wire insulation is usually rated in either 75 deg C.... or 90 deg C.

There were several surplus electrical places I used a few years back that had loads of super flexible 2 ga, and also 1 ga, and 1/0 + 2/0. I'll be damned if I can remember the name of the places. They even had it in teflon coated, good for 250 deg C. The prices at the time were very reasonable.

BTW, every time you drop down 3 gauges on the wire table the dc resistance drops exactly in half. IE: 3 ga wire is the same dc resistance as 2 x 6 ga wires in parallel. That's good info for calculating V drops, etc. However, 3 ga wire will not handle double the current of 2 x 6 ga cables in parallel. 3 ga wire is good for 100 A. 2 x 6ga is good for 140A. A single 6 ga is good for 70A.

Reason is, it's based on total combined circumference. The combined circumferences of the 2 x 6 ga wires is 41% more than the circumference of the single 3 ga wire.

You can always use some of that split loom to re-enforce any cables to further protect it from abrasion, heat, or oil etc.
 

Department Of Boost

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Did you happen to try on your KB? I have a KB 2.6. If this won't work, I found a good deal on a PA 130amp.
I'm 99% sure that the Police Interceptor alternator fit with the KB.

That PA130amp is the same as the stock Motocraft junk.

What would cause you to need the 200amp anyway? Sorry if that is a noob question. I don't run much over stock as far as electronics. I have gauges, intercooler pump and an aftermarket head unit. Would I benefit from a 200amp?
You probably don't need more amps. I went 200+ because my 2007 was running:

-3 fuel pumps full time
-3 Meziere 55gpm water pumps full time
-16" pusher fan
-2x 10" puller fans
-And the stock fan

I also have a trans and rear end coolers/pumps. They don't run much though.

Dem is some amps! The ironic part is that even the big amp alternators need to spin a little to make full power. Even with a 218amp alternator it can't keep up under 1600rpm. As soon as it goes above 1600rpm it will power a small city. But the car is not real happy sitting at lights and stuff at night.

This spring i'm going to try a smaller pulley. But it may cause the alternator to come aprt at high RPM.


This is why i went residential grade wire instead of automotive/audio grade. I use 2x #4 wires for my battery relocate in the trunk. A single #4 is capable of 100A continuous at 110v. At 12v it is considerably higher. The amp draw for a starter is massive! (Obviously limited by the battery, in such case around 550-700 cranking amps). No one big deals it since this amp load is momentary (1-3 seconds to start a car). But it makes me feel better. The next best thing for a battery relocate is welding cable 1/0 or 2/0 and that is expensive heavy shit. I use a 1/0 for battery ground. A single #4 at the alternator casing to chassis ground. I would like to join those grounds as well, just havent gotten to it yet.
I didn't know residential was different. We're bumping into my knowledge limit on electronics here.

I run welding wire for everything. I think the battery relocate wire is 0/0? Is that a thing? If not it's 1/0. Ground to chassis is the same. Alternator is #2 and the "ground strap" (motor to chassis) is #2 also.
 
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702GT

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Per the wire tables, 4 ga is good for 88 A continuous. 2 in parallel is good for 176A continuous.

3 ga is good for 100 A continuous.

Ac or dc doesn't change the ampacity of any wire. House wire insulation is usually rated in either 75 deg C.... or 90 deg C.

There were several surplus electrical places I used a few years back that had loads of super flexible 2 ga, and also 1 ga, and 1/0 + 2/0. I'll be damned if I can remember the name of the places. They even had it in teflon coated, good for 250 deg C. The prices at the time were very reasonable.

BTW, every time you drop down 3 gauges on the wire table the dc resistance drops exactly in half. IE: 3 ga wire is the same dc resistance as 2 x 6 ga wires in parallel. That's good info for calculating V drops, etc. However, 3 ga wire will not handle double the current of 2 x 6 ga cables in parallel. 3 ga wire is good for 100 A. 2 x 6ga is good for 140A. A single 6 ga is good for 70A.

Reason is, it's based on total combined circumference. The combined circumferences of the 2 x 6 ga wires is 41% more than the circumference of the single 3 ga wire.

You can always use some of that split loom to re-enforce any cables to further protect it from abrasion, heat, or oil etc.

Great information! I stand corrected on wire rating. Though it does seriously vary from chart to chart. Just doing a google yields anywhere from 80A to 100A. I also can't stress enough that this is about automotive application of wires. The majority of your high load calls will be short duration bursts (such as a starter). Obviously to do it right you'd have to size your power cables to what you *know* will be the max possible continuous load. Headlights, stereo, fuel pumps, ect,. Because I have not added any more load to the cars electrical system beyond OEM, I'm simply applying wire size for added distance to the battery, and added safety margin to alternator cable failure in the event of a full charge condition. I had not considered running 2x #6 wires for an alternator cable though, I will have to see what it looks like on a connector and see if it's feasible to fit behind the alternator, to the stud. The stud on the alternator is literally maxed out with the stock cable eyelet and nut. I may modify this setup further and drill out the eyelet to fit more completely over the stud, and place a large nylon washer between the casing and spacer, then washer and nut. I may even get drastic and fit a cable clamp to the alternator wire, seal the connection, and bolt that directly to the alternator with a big nylon washer to separate the casing/contact.

Literally the alternator cable and the output stud are the only headaches with running this particular alternator. Considering you need a cable upgrade with just about any high amp alternator anyway, that leaves the output stud as the only obsticle. And as discussed, there are several methods to acheive anyones goal for its intended use.
 

702GT

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I'm 99% sure that the Police Interceptor alternator fit with the KB.

That PA130amp is the same as the stock Motocraft junk.


You probably don't need more amps. I went 200+ because my 2007 was running:

-3 fuel pumps full time
-3 Meziere 55gpm water pumps full time
-16" pusher fan
-2x 10" puller fans
-And the stock fan

I also have a trans and rear end coolers/pumps. They don't run much though.

Dem is some amps! The ironic part is that even the big amp alternators need to spin a little to make full power. Even with a 218amp alternator it can't keep up under 1600rpm. As soon as it goes above 1600rpm it will power a small city. But the car is not real happy sitting at lights and stuff at night.

This spring i'm going to try a smaller pulley. But it may cause the alternator to come aprt at high RPM.



I didn't know residential was different. We're bumping into my knowledge limit on electronics here. Different in total diameter size. Insulation is generally thinner, and stranding is usually solid, where automotive is finer stranding which allows greater flexibility.

I run welding wire for everything. I think the battery relocate wire is 0/0? Is that a thing? If not it's 1/0. Ground to chassis is the same. Alternator is #2 and the "ground strap" (motor to chassis) is #2 also.

Nothing wrong with your setup at all. I just prefer a different route and like mine better. :) If nothing else, you can always fix an exhaust leak on the go! Just unplug your positive battery leads, rev the engine, and tac away!:wink:
 

Department Of Boost

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Nothing wrong with your setup at all. I just prefer a different route and like mine better. :) If nothing else, you can always fix an exhaust leak on the go! Just unplug your positive battery leads, rev the engine, and tac away!:wink:

I am a firm believer in rule #37. There is no "overkill." There is only "open fire" and "time to reload.":Chainsaw:

Iron Man stopped by for a recharge once.:driver:
 

wabirch

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Thanks, and I had not seen that fuse holder set up. Water resistant it seems. Nice tip as well.
 

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