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Knowledge dump: Big 7 battery cable upgrade; high amperage alternator; wiring

Discussion in '1st Gen. Tacomas (1995-2004)' started by redneck_adjacent, Aug 20, 2023.

  1. Aug 20, 2023 at 4:08 PM
    #1
    redneck_adjacent

    redneck_adjacent [OP] Well-Known Member

    Joined:
    Aug 14, 2023
    Member:
    #431233
    Messages:
    235
    Gender:
    Male
    First Name:
    Mike
    Bellevue, WA
    Vehicle:
    1997 Tacoma 2.7L 4x4 W59 MT
    5 PSI supercharger 3" lift Bilstein 5100 shocks Old Man Emu springs General Spring leaf springs with 2" blocks and extended shackles 31" Firestone Destination XT tires LCE header and catback exhaust HPS CAI Tundra S13WE front brakes KC HiLites flood, ditch, fog, and backup lights Eaton Bussmann relay/fuse panel with custom power tray All Pro bumpers, sliders, and skid plates
    TL;DR You need part numbers 90980-10868, 90980-11349, 90980-11400 in order to rebuild the alternator-starter harness on your first generation Tacoma with a 2RZ or 3RZ engine.

    I invested in the Jeep Cables Big 7 kit and 140 amp alternator from LC Engineering for my 1997 Toyota Tacoma 2.7L 4X4 W59 MT.

    There is plenty of information already on TacomaWorld concerning bespoke battery cables and aftermarket kits, like the Jeep Cables Big 7, so I won't go into detail concerning lugs, crimping, etc. Instead, I want to share information concerning:
    1. How I sheathed, configured, and installed the Jeep Cables Big 7 Kit
    2. How I approached the alternator-starter wiring harness
    Really, the second point above - more precisely, the seeming absence of any information concerning the alternator-starter harness fed by the fuse box on TacomaWorld - is the raison d'être of this post.

    Big 7 battery cable kit
    Alternator-starter wiring harness

    In addition to the cables extending to the alternator, starter, engine ground, and fender, there are wires connecting the factory fuse box, alternator, and starter by way of connectors. You can reuse those wires, pins, sockets, seals, and connectors. However, you may want to replace them completely. Below are the part numbers, which you can also find by reading the codes on the back of each connector:
    Corsa Technica's inventory is truly amazing. I strongly recommend Corsa Technica.

    If you choose to reuse your connectors but replace the seals, pins, and sockets then here are the parts you will need, all of which allow you to choose the wire gauge you want:

    When it comes to designing a brand new alternator-starter wiring harness, I suggest that you not use the factory wiring harness as a template. You will find the factory harness too big, particularly the connection between the fuse box and alternator. Designing a new harness is no doubt frustrating. Realize, however, that doing so will save material (i.e. $$$) and, crucially, minimize the risk of contact with the engine and-or air-intake system - both of which get hot! On that note, refer to the first section of this post for more information on wire sheathing and heat shrink.

    img_3070_720.jpg
     
    Last edited: Aug 24, 2023
  2. Aug 21, 2023 at 1:22 AM
    #2
    Bivouac

    Bivouac Well-Known Member

    Joined:
    Sep 5, 2021
    Member:
    #376253
    Messages:
    11,580
    Northern Lehigh Valley Pa
    Vehicle:
    2000 Tacoma 5 speed 3.4
    Remains to be seen I bought the tires and wheels the rest came along
    Nice write up:thumbsup:

    Less the alternator how much did you spend and how long?

    I have been making my own cables for years.

    I have bought many things over the years from Ballenger Motorsports.
     
  3. Aug 22, 2023 at 11:47 AM
    #3
    redneck_adjacent

    redneck_adjacent [OP] Well-Known Member

    Joined:
    Aug 14, 2023
    Member:
    #431233
    Messages:
    235
    Gender:
    Male
    First Name:
    Mike
    Bellevue, WA
    Vehicle:
    1997 Tacoma 2.7L 4x4 W59 MT
    5 PSI supercharger 3" lift Bilstein 5100 shocks Old Man Emu springs General Spring leaf springs with 2" blocks and extended shackles 31" Firestone Destination XT tires LCE header and catback exhaust HPS CAI Tundra S13WE front brakes KC HiLites flood, ditch, fog, and backup lights Eaton Bussmann relay/fuse panel with custom power tray All Pro bumpers, sliders, and skid plates
    Thank you.

    I am extremely sick at the moment with COVID so I do not have the energy to calculate the costs. More, I wonder how cost ought to be calculated anyway. Should tools (e.g. heat gun, etc.) be included?

    If you are only concerned with cost of materials then links to all of the materials are provided in my OP.

    Costs will vary according to material quality; however, when it comes to electronics, in my experience, you get precisely what you pay for. There is no free lunch when it comes to wiring, connectors, etc. Spend as much money as you can reasonably afford.
     
    Bivouac[QUOTED] likes this.
  4. Aug 23, 2023 at 3:30 AM
    #4
    Bivouac

    Bivouac Well-Known Member

    Joined:
    Sep 5, 2021
    Member:
    #376253
    Messages:
    11,580
    Northern Lehigh Valley Pa
    Vehicle:
    2000 Tacoma 5 speed 3.4
    Remains to be seen I bought the tires and wheels the rest came along
    I hope you feel better !!

    I was just curious I pretty much stocked up on my supplies back in 2018

    i tend to give away things much to cheap!
     
  5. Aug 24, 2023 at 2:58 AM
    #5
    redneck_adjacent

    redneck_adjacent [OP] Well-Known Member

    Joined:
    Aug 14, 2023
    Member:
    #431233
    Messages:
    235
    Gender:
    Male
    First Name:
    Mike
    Bellevue, WA
    Vehicle:
    1997 Tacoma 2.7L 4x4 W59 MT
    5 PSI supercharger 3" lift Bilstein 5100 shocks Old Man Emu springs General Spring leaf springs with 2" blocks and extended shackles 31" Firestone Destination XT tires LCE header and catback exhaust HPS CAI Tundra S13WE front brakes KC HiLites flood, ditch, fog, and backup lights Eaton Bussmann relay/fuse panel with custom power tray All Pro bumpers, sliders, and skid plates
    OP edited to reflect new learning.
     

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