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Old 12-20-2014, 06:01 PM   #1 (permalink)
bowtiebutler956
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Upgrading To A CS144 Alternator

The alternator went out on my 93 K2500, which didn't surprise me, as it was an inexpensive CS130 I got on ebay that was supposed to be upgraded to a 160 amp unit. Well it didn't actually quit charging. Something was draining my batteries overnight, and I traced it to a 4 amp draw from my alternator, which meant it had a bad diode. I'd never been very happy with this alternator because when I was idling with the A/C on, headlights, stereo, etc.. it would drop to about 13v, and as soon as the rpm's came up, it would go back to about 14v.

I decided to spend an extra $20, and upgrade to a CS144, which is a larger alternator, and the one I got is rated at 140 amp, as opposed the stock CS130 being rated at 105 amp. Here is the Orielly listing for my new alternator. Ultima 8219-5B - Alternator | O'Reilly Auto Parts
The real difference with the bigger alternator, is its charging power at idle. This alternator stays at 14v or above, even with the A/C, headlights, stereo, running while idling in drive.
It was almost a direct swap. I had to make an upper bracket to replace the factory angled one, because the upper ear on the CS144 is much wider, and more robust. A piece of 1" wide strap worked perfectly after drilling a couple holes in it. I also had to purchase one 3/8"x3" long bolt, to use on the alternator. I had to get a slightly longer belt as well. I used a 6K1015 in place of my original 6K1005. I'm aware that most the factory alternators use an extra support bracket on the back of them, but mine was missing when I got my truck, and I never had a problem. It should be stronger than before, as the larger alternator has a much stronger upper mounting ear than the one it replaced. The plug for the CS144 is the same one used on the CS130, so everything plugged in, and worked perfectly. I had already upgraded the charge wire going to the alternator to a 4ga. wire, so that was already good to go. I took pics to show the differences in the alternators, as well as the new upper bracket. I think this swap should be the same for trucks up to 95 , or the ones that have the alternator on the drivers side. Thanks

Matt

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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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Old 12-20-2014, 07:05 PM   #2 (permalink)
JMJNet
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Do you happened to remember the length for that metal strap?

I installed one in mine but I am using a series of nuts and a long bolt on the angled strap.
I am thinking of making that flat strap before it breaks.

Thanks.

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Old 12-20-2014, 07:26 PM   #3 (permalink)
bowtiebutler956
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Quote:
Originally Posted by JMJNet View Post
Do you happened to remember the length for that metal strap?

I installed one in mine but I am using a series of nuts and a long bolt on the angled strap.
I am thinking of making that flat strap before it breaks.

Thanks.
I cut the strap to the same length as the original was. I didn't even measure it, I just layed the original bracket next to my 1" strap, and made a mark with a piece of chalk, then cut it. Likewise with the holes I drilled. I layed the OE strap on top of my new piece, and using chalk, I marked where the holes needed to be drilled. The strap I used is 3/16" thick, where the OE was only 1/8". I buy my steel from my local steel supply, but this was just some leftovers I had in the shop. You can buy 1" strap in 36" or 48" lengths at the Home Depot, or Tractor Supply.

Matt
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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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Old 12-20-2014, 09:33 PM   #4 (permalink)
JMJNet
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Quote:
Originally Posted by bowtiebutler956 View Post
I cut the strap to the same length as the original was. I didn't even measure it, I just layed the original bracket next to my 1" strap, and made a mark with a piece of chalk, then cut it. Likewise with the holes I drilled. I layed the OE strap on top of my new piece, and using chalk, I marked where the holes needed to be drilled. The strap I used is 3/16" thick, where the OE was only 1/8". I buy my steel from my local steel supply, but this was just some leftovers I had in the shop. You can buy 1" strap in 36" or 48" lengths at the Home Depot, or Tractor Supply.

Matt
Got it. Thanks.
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1995 GMC Suburban:
PMD in Bumper
Leroy Diesel Flight System PMD
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4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator
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Old 12-22-2014, 10:04 PM   #5 (permalink)
nh484000
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Anyone know if you can run twin cs144? I run twin cs130 that work well at higher rpms but at idle I could use more power especially when they heat up.
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Old 12-22-2014, 10:10 PM   #6 (permalink)
Freddyack
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Just checked Oreilly's. None of the stores around here stock it. Did you have to order yours?
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Old 12-22-2014, 10:19 PM   #7 (permalink)
bowtiebutler956
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Quote:
Originally Posted by nh484000 View Post
Anyone know if you can run twin cs144? I run twin cs130 that work well at higher rpms but at idle I could use more power especially when they heat up.
If you can run 2 of the CS130's, then you can certainly run 2 of the CS144's, as long as you have the clearance for a slightly larger alternators. It would require you to do some bracket work as well, like I did for mine.
I'm curious, what are you doing with your truck that needs that much juice?

Quote:
Originally Posted by Freddyack View Post
Just checked Oreilly's. None of the stores around here stock it. Did you have to order yours?
Yes, I ordered it Freddy. With Oriellys, the part is always in by the next morning, but in my case it came from another store about 20 miles away, so I got it same day.

Matt
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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear

Last edited by bowtiebutler956; 12-22-2014 at 10:22 PM.
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Old 12-22-2014, 10:22 PM   #8 (permalink)
Freddyack
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OK, thanks. The warehouse for this area is about 5 miles from my house. So I can pick one up if they have it "at the warehouse"

Do you have the factory vacuum system or a Turbo Master? Just trying to figure out the serp belt size I will need.
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Last edited by Freddyack; 12-22-2014 at 10:24 PM.
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Old 12-22-2014, 10:39 PM   #9 (permalink)
bowtiebutler956
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Quote:
Originally Posted by Freddyack View Post
OK, thanks. The warehouse for this area is about 5 miles from my house. So I can pick one up if they have it "at the warehouse"

Do you have the factory vacuum system or a Turbo Master? Just trying to figure out the serp belt size I will need.
Your lucky to have your warehouse that close. Down here the warehouse is in Houston which is 350 miles north of me. I'm sure they'll have it at the warehouse. If you click the compatibility chart in that link I posted, you can see this alternator was used on alot of GM applications.
My truck is a 93, so it never had the vacuum system, and I'm running an HX turbo on it. On mine, I had to go up 2 belt sizes, from a 6k1005 to a 6k1015, so whatever belt you have now, try going up 2 sizes. Worst case, you have to exchange it for a different one. I bought 2, and returned the one I didn't use.

Matt
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93 K2500, 4x4, 160,000 miles, 4L80E, Ext Cab, F code 6.5TD, GU6 3.42's, G80 Posi.
HX40WII CKO Turbo with genuine Holset compressor, and wheel. 56/83
PT Wiring Solutions HX installation kit, and wastegate.
31x12x3 Air to air intercooler, Peninsular upper intake, K47 air box.
Custom 2831-5079 IP by DieselPro with genuine Bosch Germany 311 nozzles popped to 2250 by DieselPro
3" Diamond Eye downpipe from Leroy Diesel with homemade 4" exhaust.
HO water pump, 190 Delco T-stat, 9 blade steel cooling fan, Modified fan clutch for early engagement.
CKO "Improved" heads, ported, with diamond precups, +.010 Felpro's, and ARP head studs.
Superior 4L80E shift kit. Manual TCC Lockup Mod.
3" lift in the front, 2" in the rear
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Old 12-22-2014, 11:49 PM   #10 (permalink)
90GMC62L
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Did it already come with a 2-5/8" pulley as well? I wouldn't mind upgrading mine someday. It doesn't have a draw but it seems to have a problem holding 14V at idle sometimes. You can definitely tell when I turn on lights and other accessories, my truck will idle down a bit and i'm not sure that's right. And you are right, your exact swap will work for 92-95 6.5s and even 88-93 6.2 trucks in the GMT-400 style.

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Last edited by 90GMC62L; 12-22-2014 at 11:53 PM.
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