DC Power Engineering h.o. alternator issues

I guess it adds up fast once you put all that in

I wish the oem was at least 100 amps instead of that wimpy little 80 amp one we have

 

Yup. Idk what the idle output is on the oem, but that's the biggest deciding factor on getting the dc. 120 hot idle amps. There's like almost zero strain on the system now. You can hear it when I first flick the lights on, but it adjusts right away and evens out. And will eventually be getting a dual battery too. That's another thing. Running the lights AND the stereo all off one battery causes fluctuation in the output of the alt and causes strain on the lights. At least that's what I assume. Having the lights and winch dedicated to a second battery, with the stereo on the main, should help. Idk I gotta do more research into dual battery setups. It'll be quite a while before I do all that though. But at least I've future proofed myself with this alt. And DC seems to have great customer service so I shouldn't have any problems if anything else comes up.

 

Thanks for the link.

 

those dc power alternators are nice. i picked up a singer for my 3rd gen runner.

 

Welp, Just had another issue. Now the damned adjustment bolt on the lower alt bracket broke. Sigh.. Its gotta be this dc alt not being 100% perfect fit. Something is obviously not right making it keep doing this, and Idk what. Because I torqued everything down last time, and tightened the belt perfectly. I did do some offroading recently as I haven't in quite a while. So the extra vibes might be causing it to get stressed even more. Seems like this happens shortly after I do go offroading now that I think about it. For now I'm just gonna order up a couple extra of the adjustment bolts as well as another bracket. If it happens again, probly gonna contact dc and see what they say. If nothing else, I'll be looking for a different alt.

 

might just be heavier or something but at least you pinned it down to when your off roading so you know its added stresses from bouncing around

the top has good support but can you add an extra bracket to the bottom of it to support the bottom side so its rock solid? that might solve all the issues if you can figure a way

 

now dont go all gorilla on those bolts this time lol

 

That bolt is definitely one that you don't want to overtighten. Just get it cinched with the belt so it has good tension and everything operates as it should, any more and the belt will be working against you and putting undue stress on the bracket.

 

That's the thing. I did just get it cinched on there. I torqued the top bolt to like 35 iirc. The bottom bolt I put a nylock on and barely tightened that one as well(the one that broke that has the threaded insert for the adjustment bolt to thread into). I tightened The belt first before tightening that bolt. Then I literally barely tightened the adjustment bolt again just to have make sure it wouldn't fall out as it seemed too loose. It's like there's too much stress on it regardless of what I do. Any looser and the alt will loosen up and the belt will slip. I was actually expecting that because I thought things WERE too loose last time.

Idfk.. I don't think there's any way to further reinforce it with an extra bracket or anything either. Certainly don't have the tools to make one. I'm wondering if I should try hardened washers instead of the tiny spacer they have in there for that lower bracket and bolt. Think I will. Just don't see how that'd help now that it's the bolt that broke and not the bracket.

 

It almost sounds to me like that bracket is too short for the new alternator, though from looking at the original picture again, it looks kinda like the spacer is not the right size. Something is definitely not spec.

 

Negative. If you look at my previous pics you can see where it get a tightened down. And the top bracket was a really tight fit. Kinda seems like the spacer in the top was a hair too long, that it's not getting tightened down on the alt and bracket itself but the spacer instead, allowing it to come loose on top. Now that I think of it that be the issue. Its probly not getting tight enough on top, but only the bottom causing more stress on the bottom components. Probly why the case cracked last time because I tightened it too much. Idk. I feel I should contact the company again and see what they say. Doubt many tacoma owners actually use this alt. I may be the only one. Ha. Maybe there's fitment issues they aren't aware of.

 

I think I just figured it out guys.. I think this design, is just not a good one. If you look at the pic, the top support uses this long spacer that is pressed into the front billet case on the alt. And there's no support in the back. So most of the weight is being transferred down on the lower components. I would think the top support would be enough, but it's gotta be that.

Compare that to an oem one or the singer that @ramonortiz55 posted above. You'll see that it has an extra case support for the rear as well! Might not be the issue, but certainly seems like it's a possibility. Its too damned heavy, along with the extra turning torque required on this alt, I bet it's flexing under load, as well as extra vibrations and stress while offroading!

 

so what do you plan to do @NightProwler

 

Idk man. Gonna try this again. I'll be on the lookout for another alt if something breaks again I guess. Whatd you pay for yours and what's the ratings on it? Their site only has an inquiry form I see..

 

I think I paid like $300 for it, more or less.

Took a month to get it since he builds them to order.

The max amp output is about 275 amps, which I asked for due to my winch setup.

 

Nice. Know what the idle output is? Should be good if it can run your winch tho. I got lots of lights and my sub..

Might try to sell my alternator. Probly throw it up on Craigslist. If something breaks again. Won't sell it here tho.. Ha. Not gonna play anyone like that. Its a great alt. Just has the fitment issues. I swear it's that and not me. Never had a problem before until that one went in. Idk I might try to mess with it more and see if I can get it mounted better. Just kinda ridiculous since I paid $400 for it and having issues. I'll call dc and see if they've had any other issues. Or sdhq. They sell them and have nothing but good praise. Said they I stall them on a lot of rides including tacos.

 

Any update on this? Wanted to give a shout out since I've been running a DC Power 180A alternator since March, 2015 for approximately 9K miles. I haven't had any issues with it so far (fingers crossed), but have had mixed experiences in the past with aftermarket parts so I hear ya. I don't recall paying too much attention to the adjustment nut torque. I just put some blue locktite on it and made sure it was snug. I will say that the bottom mounting hole is deeper (thicker) than the factory alt, and the lock nut was barely flush with the top of the threads, whereas the the stud protruded several millimeters beyond the nut with the factory alt. It was a little disappointing but I suppose if I ever send it in for servicing, I may see if they will machine down that mount a little. I talked with a local shop about it and they didn't think it was of any concern.

Let us know what could have caused the damage to the case, and the broken adjusting brackets. I may put one or two in the parts bin before my next adventure.

 

Well I haven't had any issues as of late. Haven't done much offroading lately. I was concerned the extra vibes might affect it. But I believe the case broke because I tightened it down a tad too much. And I mean literally a tad. It's just snug in there now. Including the lower alt bolt. Hasn't come loose on me and cause slipping. Yet. So I believe its just more sensitive to torque, as far as the top bolt goes. And the bottom, well, I have no idea. But I got spares in my truck ready for it. And yeah, they should have included a special extended bolt for that lower mount. Or like you said machined it down thinner.

 

Good to hear. Did you purchase the replacement brackets from the dealer, or were they aftermarket from a local parts house? Not even sure if you could get them from anywhere other than a dealer. Yeah, there is no way to make that stud longer unless you were to fabricate a longer tensioner bolt, or get one from another manufacturer.

 

Yeah from the dealer. Was afraid anything aftermarket wouldn't be as strong. Besides, was about the same price. Got one new bracket on now, with a spare, and two spare tensioner bolts and nuts, in my truck ready in case it breaks again. Ha. Kinda sad I had to resort to that. But oh well. Should last me a long time. Until I decide to upgrade my whole system to a dual battery setup with a fancy relay box for all my lights, along with probably Even more lights by then, and my sound system. At that point is when I'll probly change up the alt too to something different. 'If' I have any more parts break. Should still be sufficient and enough to power all that with a dual bat setup. Idk. Haven't looked into it much. That's in the far future.