87-278-3 May 1996 How to Convert 3G Series Alternators to Replace Mitsubishi for Ford N THE LATE1980’S MITSUBISHI produced two alternators for Ford: The A3T01598 (WAI #1-1180-02MI, Lester #13190) was used on 1988-90 Tempo and Topaz and has a 1-groove pulley; the A3T01596 (WAI #1-1180-01MI, Lester #13188) was used on 1988-89 Taurus and has a 6-groove pulley. These alternators are exactly alike except for the type of pulley they require. Figure 1. Hard- to-get Mitsubishi alternators for Ford like this one can be replaced with a converted 3G unit. The cores for these two alternators can sometimes be hard to find. However, with the addition of a con- version plug, you can build 3G units to replace the Mitsubishi units. Components Needed to Build Replacement Units To build 3G units to replace these Mitsubishi units, use the following components: ¢ Small D.E. frame with 135 mm OD and the adjusting ear at 10:00 when viewed from the S.R.E. end (WAI #21-211). ¢ Late-style small-frame rectifier with 135 mm OD (WAI #31-207). Has extended hex nut and attached washer (WAI #85-2305) on the rectifier battery terminal. (See Figure 2.) * Late-style S.R.E. frame with diamond-shaped i Wetherill Associates, Inc. + 1101 Enterprise Drive – Figure 2. Use the rectifier assembly on the right, with the extended hex nut & attached washer on the battery terminal. battery-terminal hole (WAI #22-206). (See Figure 3.) ¢ Small-frame stator with 135 mm OD. If you are salvaging stators, the color of the insulating varnish indicates the amperage, as follows: Green: 75-amp Purple: 85-amp No color: 95-amp Figure 3. Use the S.R.E. frame with the diamond-shaped battery-terminal hole, shown on the right. If you are using a new stator, you can use WAI #27-209 (95-amp). * Regulator E9DZ-10316-A, FODZ-10316-A, GR801 (WAI #35-204). ¢ Conversion plug adapter and battery-post insulator (WAI #46-2805). (See Figure 4.) ¢ Terminal cover (WAI #46-2852). ¢ Either a 1-groove pulley for use on 1988-90 (Continued on back) Royersford, PA 19468 +» 800-877-3340 Care is taken to ensure the accuracy of information presented here, but Wetherill Associates, Inc., assumes no responsibility for possible errors. Copyright © 1996 Wetherill Associates, Inc. 4977 Tempo and Topaz (WAI #24-2104) or a 6- groove pulley for use on 1988-89 Taurus (WAI #24-2254). Figure 4. This conversion plug and cover are the key to converting 3G units. How to Convert Existing 3G Units You can also convert existing 3G units to replace these Mitsubishi units. All you have to do is remove the insulator on WAI’s 20-225-31 and 20-225-32 units and install the conversion plug and cover above. (See Figure 4.) Please note that although both of the Mit- subishi units are rated at 75 amps, our testing has shown that their maximum output is actually well above the 75-amp rating. But also note that all alternators are designed to operate at max- imum output for only short periods of time. Figure 5. The converted 3G unit. Warning The battery-terminal connection on these alternators is susceptible to the same kind of burnup that can occur on Ford IAR units, so the installer must be sure to inspect the vehicle’s wiring harness and replace it, if necessary, with a new plug adapter (WAI #46-2801 or 46-2801- 1). To ensure a tight, sealed connection, the installer should also be sure to apply electrical contact gel to the plug (WAI #89-262). For more details on how to prevent burnup caused by a poor connection at the battery ter- minal, see Technical Update 3 (November 1992). WAI No. 20-225-31 20-225-32 21-211 22-206 24-2104 24-2254 27-209 31-207 Description 95-amp 3G alternator for Ford 95-amp 3G alternator for Ford D.E. frame S.R.E. frame 1-groove pulley 6-groove pulley 95-amp stator Rectifier WAI No. 35-204 46-2801 46-2801-1 Description Voltage regulator Repair harness Repair harness w/ butt connectors & shrink tube Conversion plug adapter Terminal cover Extended hex nut w/ attached washer Electrical contact gel 46-2805 46-2852 85-2305 89-262