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Hodges87
09-21-2009, 06:25 AM
96-98 Vortec Alternator Upgrade AD244

If you want to upgrade your alternator and don't want to modify your wiring harness, heater hose tubing, and buy an additional bracket the AD244 is the way to go. Its a direct bolt on replacement, the only thing you will need is the belt made for running the 140 amp alternator (its available at any part store just ask for a belt and tell them you have the 140 amp alternator) Its a very easy upgrade, routing the new belt took longer than installing the alternator, lol.

Here is side by side comparison of the stock CS130D 105amp alternator that came stock in the 96-98 Vortec's and the newer AD244 (130-145amp that comes in the NBS trucks (99-05 only)


http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/comparison.jpg
Image provided by FUCTUP

http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade8.jpg

http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade9.jpg

I picked my alternator up at a local salvage yard for $50 w/30 day warranty
http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade1.jpg

As you can see my original wiring harness plugs right in
http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/plug1.jpg

http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade2.jpg

The heater hose tube has plenty of clearance also:
http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade4.jpg

http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade6.jpg

Here are some before and after pics of the install:

With the factory CS130D 105 amp
http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/beforead244.jpg

With the AD244 145 amp installed
http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/AD244upgrade7.jpg

daved931
09-21-2009, 07:50 AM
Great tip. I'm going to have to try this.

Hodges87
09-21-2009, 10:26 AM
More info on the upgrade http://www.youtube.com/watch?v=aOPcnX7V7i4

bigtfw2000420
09-21-2009, 11:42 AM
wow so just go to oreillys and tell them i need a alt for a 99 half ton with 5.3 more or less

Hodges87
09-21-2009, 12:46 PM
Yeah but make sure its a 130 or 145 amp and it looks like the one above, and purchase a new belt for a 140 amp alternator. I bought mine at a salvage yard for $50 w/30 day warranty. If it goes out after the 30 days I'll just rebuild it myself. I've put 100 miles on it so far and its working great.

wild_chld1
09-21-2009, 08:45 PM
the alt is just plug and go aside from a new belt

JZ57_CN
09-21-2009, 10:08 PM
Hodges87,

Thanks for you 1st hand experience and writing.

You may right on physical swapping. But based on manufacturer's statement CS-130 and AD244 regualtor are controled by different conception. CS-130 is controled by internal regulator only; AD244 is controled by both internal regulator and PCM, it has a lot of fuel efficiency function involved.

After the swapping, how is the electric output performing?



[QUOTE= Hodges87 wrote: 96-98 Vortec Alternator Upgrade AD244[/SIZE]

If you want to upgrade your alternator and don't want to modify your wiring harness, heater hose tubing, and buy an additional bracket the AD244 is the way to go. Its a direct bolt on replacement, the only thing you will need is the belt made for running the 140 amp alternator (its available at any part store just ask for a belt and tell them you have the 140 amp alternator) Its a very easy upgrade, routing the new belt took longer than installing the alternator, lol.

Here is side by side comparison of the stock CS130D 105amp alternator that came stock in the 96-98 Vortec's and the newer AD244 (130-145amp that comes in the NBS trucks (99-05 only)

http://www.jrhodges.com/modules/N4G-SigHost/images/sigs/comparison.jpg

wild_chld1
09-21-2009, 11:14 PM
sorry for the typo,what i was askin is the alt just plug and go

Hodges87
09-22-2009, 06:26 AM
Yes, Its is working great. The voltage requlator controls the voltage not the pcm. The voltage regulator has a set rate example 14.7, the more power that you use, the harder the alt works so it can maintain the 14.7 volts. Correct me if I wrong, but this is my understanding about alternators.

Also the Alt uses the factory plug with 1 wire, and I'm sure the one wire goes to the volt meter gauge, I might even upplug it to test this theory. The pcm wouldn't be able to control it. (I'm not an expert so correct me if I'm wrong)

Watch the video I posted and that will give you a little more insight.

sonjaab
09-22-2009, 09:19 AM
JZ...........He don't wanna hear it!

Hodges87
09-22-2009, 09:33 AM
JZ...........He don't wanna hear it!

Watch the video! This guy knows alternators!

fire730
09-24-2009, 09:54 PM
Thanks for the heads up. I may be replacing my alternator sooner than I think. Any bolt-on upgrade is perfect. My alternator drops below 12 volts at idle with the headlights on but above idle it is fine.

Da Burb
09-25-2009, 03:09 AM
I did this swap a couple of months ago.
Totally plug and play...no issues!!!

bigtfw2000420
09-25-2009, 11:21 AM
I did this swap a couple of months ago.
Totally plug and play...no issues!!!

so u buy the alt and a new belt and thats it

daved931
09-25-2009, 12:22 PM
I'm probably going to try this over the weekend.

CKTA
09-25-2009, 12:36 PM
What belt part #'s are you guys using?

cichlid_baby
09-25-2009, 02:18 PM
When I did my HO alt install.. I just took the stock belt which I had just removed with me to the local AutoZone (you can use any autoparts store) and just tell them to match you up with the same belt but an inch longer. This is much easier and cheaper than trying to find a correct GM parts number.

Da Burb
09-25-2009, 03:10 PM
My belt is different because I'm also running the Whipple.
Go to a 'Gates' belts supplier and try a few out until you get the right size.

Hodges87
09-26-2009, 10:04 AM
Goodyear Gatorback belt # 4060967
I bought it at autozone for 35.99

Da Burb
09-26-2009, 04:24 PM
Here's mine sitting in it's home.

http://img.photobucket.com/albums/v35/hquick/AD244%20Alternator/P7200046.jpg

http://img.photobucket.com/albums/v35/hquick/AD244%20Alternator/P9270005.jpg

http://img.photobucket.com/albums/v35/hquick/AD244%20Alternator/P9270008.jpg

And here you can see on the right it says 145A

http://img.photobucket.com/albums/v35/hquick/AD244%20Alternator/P9270009a.jpg

Hodges87
09-26-2009, 09:33 PM
I grabbed the 130 amp. When you buy one of these alternators always look for the 145a marking. I was in a hurry and grabbed a 130 amp, it works great, same casing, exactly the same as the 145 amp but -15 amps.

xxEMOxx
09-29-2009, 07:26 PM
Do you know if this will work on a TBI 95?!! Otherwise is there a similar option for the TBI's like off a 3/4 ton or a 454 maybe?!

Hodges87
09-29-2009, 08:12 PM
Do you know if this will work on a TBI 95?!! Otherwise is there a similar option for the TBI's like off a 3/4 ton or a 454 maybe?!

oldred95 upgraded his alternator to a CS144 and he has a 95 chevy, try searching some of his old posts or send him a pm. I don't think the AD244 will work on 95- models but I could be wrong.

daved931
10-09-2009, 12:40 PM
I picked up the alternator and belt today. Looking forward to upgrading tomorrow.

Got my 1/0 welding cable and lugs to upgrade cabling, but I don't own a swage tool anywhere near big enough. I guess I'll have to trim the cables to length and take them back to the welding supply store to get the ends put on.

Hodges87
10-09-2009, 02:10 PM
I picked up the alternator and belt today. Looking forward to upgrading tomorrow.

Got my 1/0 welding cable and lugs to upgrade cabling, but I don't own a swage tool anywhere near big enough. I guess I'll have to trim the cables to length and take them back to the welding supply store to get the ends put on.

I need to upgrade my cables. Did you go all black or do they offer red cables? How much did it cost?

daved931
10-11-2009, 04:53 PM
I need to upgrade my cables. Did you go all black or do they offer red cables? How much did it cost?

I bought black and red from www.weldingsupply.com. I don't remember what I paid exactly, but the pricing was very good.

I picked up a 130 amp alternator from a local parts store for $150 + $38 core charge. I asked for one from a 2000 Silverado with a 5.3. I picked up a new Goodyear Gatorback serp belt while I was there as well. I didn't get the number off it, but I can if anyone is interested.

Alternator dropped right in place of the stock 105 amp unit. My coolant bypass hose ran into the boss on the housing for one of the screws that hold the alternator body together. I had to disconnect the hose, install the alternator and then space up the hose and put in a longer bolt.

Here are the alternator and belt in place. You can see the bypass hose raised up and unbolted.

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs270.snc1/9718_517664589389_53800192_30805393_4361393_n.jpg

Factory wiring plugs right in. My weatherpack connector plugged into the bottom from the factory, but there was enough slack to make it to the top on this alternator.

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs250.snc1/9718_517664594379_53800192_30805394_2892371_n.jpg

Here you can see the longer bolt with washers spacing it up. I'll put a nicer spacer in when I get the lugs put on my new cables. Just gotta go to the welding store and use their swage tool.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs250.snc1/9718_517664599369_53800192_30805395_7002229_n.jpg

Very straight forward swap and everything seems to be working quiet well. Looking forward to the next rain storm to run GPS, cell charger, lights and wipers and not see my volt meter dip down. :D

Hodges87
10-12-2009, 04:31 PM
daved931, thanks for the link. I guess I was lucky I didn't have to modify my coolant bypass at all but your install looks great.

RTCamaroSS
10-12-2009, 06:01 PM
Great thread guys. I wouldnt mind having that part number Daved931... I have a 145A AD244 on the way, should be here by friday. I ordered it off of ebay for 100 bucks plus shipping. I upgraded my positive cable from the my Optima yellowtop to the alternator already, so its good to go. I also added a new ground to the block and body of the truck. Cant wait to get the new alternator in!

Hodges87
10-12-2009, 06:08 PM
Goodyear Gatorback belt # 4060967
I bought it at autozone for 35.99

Here is the part #

RTCamaroSS
10-12-2009, 06:43 PM
Here is the part #

Thanks! Gunna order it now...

daved931
10-12-2009, 07:53 PM
Thanks, Hodges! It's cold outside, so I'm glad you came up with the number! :lol:

The Fiddle
10-13-2009, 10:53 PM
Plug in and go with a new belt? I like it.

RTCamaroSS
10-19-2009, 03:30 PM
Got my new alternator and belt.. ready to install but its raining outside right now :( Strange though, my alternator looks just like the ones posted, but mine says "DR44G" on it, but luckily, it always has the 145A stamp :)

Hodges87
10-19-2009, 04:14 PM
The DR44G might not work, it might have the 2 pin plug, you need the 4 pin plug. Check your plug to confirm this.

RTCamaroSS
10-19-2009, 04:23 PM
Well, install went smooth. It plugged right in no problem.

Hodges87
10-19-2009, 04:30 PM
Well, install went smooth. It plugged right in no problem.

Sweet! Now you have to do the big 3 upgrade next. Just for future reference some DR244G alternators have the 2 pin plug for the 05+ trucks and will not work. The AD244 alternators are for 99-04 trucks and have the same plug as the 96-98 chevys

RTCamaroSS
10-19-2009, 05:40 PM
Didnt know that.. i guess i got lucky, haha. Forgot to mention that i did upgrade the wiring to the alternator and upgraded the grounds. I have an Optima battery, so factory hookups went to the side terminals and i bought some top post terminals and cable so i could run a new ground to the body, new ground to the engine block, and new alternator cable straight to the alternator. Yesterday i installed an Accel coil, too. Truck seems to be running great now :)

JZ57_CN
10-19-2009, 07:23 PM
How much did you pay for your DR44G alternator?





Got my new alternator and belt.. ready to install but its raining outside right now :( Strange though, my alternator looks just like the ones posted, but mine says "DR44G" on it, but luckily, it always has the 145A stamp :)

RTCamaroSS
10-20-2009, 09:50 PM
How much did you pay for your DR44G alternator?

I got it for 99 dollars plus 15 shipping (i think) on ebay.

garagemethods
10-20-2009, 10:10 PM
awesome upgrade.

plannin on redoing my system and this was just what i needed to hear about a new alt.

cichlid_baby
10-27-2009, 09:03 AM
Found some more interesting info on this alternator...

http://67-72chevytrucks.com/vboard/showthread.php?t=342399

cichlid_baby
10-30-2009, 10:10 AM
From what I have been told and been able to research....


Regarding to the DR44 and DR44G alternators more commonly found on the newer GM trucks, besides having the two pin regulator connector.. another major difference with this unit compared the the AD244 alternators is that on the DR44 and DR44G the bridge rectifier is embedded and fused into the rear casing to form one single part where as on the AD244 the bridge rectifier is completely removable and upgradeable.

Standard on the DR44 and DR44G are 50 amp diodes in the bridge rectifier and double wound stators which is the same as in the AD244, however the on the AD244, the bridge rectifier can be easily replaced with one that utilizes much larger rated diodes (up to 70 amps). This makes the AD244 much more versatile and durable from a rebuilding standpoint.

With slight modifications, the 2 pin and 4 pin voltage regulators on these two units can be interchanged with one another. This is more so a mounting modification as there are some slight clearance issues.

In my opinion, it would make more sense to just get the older AD244 units versus the newer DR44 and DR44G units.

However, if you already have a DR44 or DR44G unit and want to be able to use it in your older vehicles that uses the 4 pin connector, it would be much easier to just replace the 4 pin male connector with a newer 2 pin male connecter and wire it appropriately (local scrap yard has plenty of connectors). Check with your local alternator guru for proper wiring. I believe there are some connector adapters/converters available that would be able to accomplish the same as well. This might be easier and cheaper than taking the alternator apart to replace the voltage regulator.

I have no personal experience with this but this is the information that I have been able to find.

Djkyle65
01-11-2011, 05:17 PM
Did any of yall who did this notice that your gator back 4060967 belt felt extremely tight?
I just purchased the stuff to do mine and had a hard time getting it on there.
Im kinda worried the belt is to tight.

Da Burb
01-11-2011, 06:34 PM
Yep....belt is tight because the case is lghtly larger (overall diameter is bigger whih moves the pulley further away). If it's too tight....get the next size up belt.
My belt is SUPER tight but I'm happy with that due to less slippage with the blower.

Djkyle65
01-12-2011, 08:08 AM
Yeah I realized it was slightly larger i just figured with the 1" longer belt the 4060967 provides it would be fine. I guess ill just run it and see what happens.

bored&stroked
01-12-2011, 11:00 AM
Why not just return it for the next size up? Sounds like lazyness that could turn into bearings getting worn out prematurely from over tightening.

helo
01-13-2011, 06:51 AM
Did any of yall who did this notice that your gator back 4060967 belt felt extremely tight?

Hah, I was just thinking this the other day after I swapped engines. Went from '89 to '96 5.7. I'm seriously thinking about getting the next bigger belt, because my tensioner is hella tight with the 967 belt. Perhaps 4060970 or 4060975.

I'm rebuilding one of my AD244's today. 240amps, wheee =).

Djkyle65
01-14-2011, 06:38 PM
Why not just return it for the next size up? Sounds like lazyness that could turn into bearings getting worn out prematurely from over tightening.

Not lazy just thought sense everyone else says to use and its the belt recommended for 140a alternator i might have something wrong...

Thanks

mattillac
03-24-2012, 11:44 PM
Thanks for the info, my 99/OBS now has an AD244 and new belt under the hood.

O'Reilly auto parts:
1 GAT K060966 39.99 / belt
1 USL 391611 149.99 / alternator
Core charge was 5.00
Tax came to 18.52

Grand total was 213.50 and is took about an hour to install.

The belt I went with was for a 99, 5.7 with the 140a alternator option.

There doesn't seem to be much extra force being exerted via the tensioner/spring
but I am noticing how much closer that new slightly longer belt is to the tensioner housing with that larger AD244 in there.

Pic of the old:
http://i267.photobucket.com/albums/ii319/mattVillac/phonepicturesandroid052.jpg

Pic of the new:
http://i267.photobucket.com/albums/ii319/mattVillac/phonepicturesandroid066.jpg

Thanks again for all the helpful info.

91chevZ71
03-13-2014, 10:59 AM
Not sure because I haven't tested it and stuff, but I think only the '03+ trucks control the alt's output with the PWM feature. GM probably did this because it is smart and the '05 FSCs have electric fans and the alternator needed to be stepped up and at idle. Probably helps the PCM minimize drag when it can reduce the alt's duty cycle when there is less amp demand and vice versa.

Comparing the pinouts of each harness (99-02 vs 03-07) they both have C2 (Green for '03 up, Red for 99-02) 15 as a brown wire for what my diagram calls "Generator Turn on, L signal" which in the real world is the voltage level signal but only the 03-07 has the C2 (Green for '03 up, Red for 99-02) pin 75 "Generator Duty Field Signal" for PWM control. I don't have an '03+ truck to go check but I guess it makes sense.

The AD244s from 99-02 probably default to the max current they can make at whatever RPM they're spinning at like every other alternator out there, but it seems that the PWM control is +03 and up specific.

Then there is the 2-pin square connector DR44G (looks exactly like an AD244 to me) alternator for the '05+ FSCs. The '05+ alternator probably has a better rating down low at idle for the fans that came stock as well as retaining the PWM feature of the '03+ PCMs.

I'm not sure if the 0411 computer can control the PWM alternators, my 99-02 pinout says that C2 pin 75 is not used so I take it that it cannot.

Bought a new alternator for the Tahoe after reading a little bit more about it, that's why I posted. Like I said, I can't confirm that the '03-'04 trucks use PWM alts (no '03+ in my driveway) but there is a pin in that harness for it.
I did get the longer belt when I swapped out the old L31 alternator for the AD244, works great.

bored&stroked
04-13-2014, 03:31 PM
After re-reading all of this, I have to ask: what's the point? Our trucks already had a 140amp alternator option, what's the reason for the new style besides 5amps? I'd understand if we could modify the obs to control output with the PCM like newer trucks but we can't so what's the big upgrade here?

Xcbullet
04-13-2014, 06:16 PM
That Vidio tells that the rectifier is better stays cooler.

sunburnedaz
04-13-2014, 11:27 PM
After re-reading all of this, I have to ask: what's the point? Our trucks already had a 140amp alternator option, what's the reason for the new style besides 5amps? I'd understand if we could modify the obs to control output with the PCM like newer trucks but we can't so what's the big upgrade here?


The AD244 when its not PCM controled works like CD130D so it can work like our trucks. Now as for the reason people upgrade. 1, its got better bearings and better cooling so they last longer. 2, its got a better diode pack design so they dont fail as often and can have higher output. And the big reason isthe AD244 145amp version is underrated from the factory and can put out more at warm idle than the CS144 and the CD130D at warm idle.

Fast305
04-14-2014, 07:28 AM
The AD244 when its not PCM controled works like CD130D so it can work like our trucks. Now as for the reason people upgrade. 1, its got better bearings and better cooling so they last longer. 2, its got a better diode pack design so they dont fail as often and can have higher output. And the big reason isthe AD244 145amp version is underrated from the factory and can put out more at warm idle than the CS144 and the CD130D at warm idle.

I still have my original CS-144 and it still works great. I have seen the voltage dip a little on a hot summer night, with the a/c fans both on high, the Tahoe fans on high (40 amps alone), and other electrical gadgets turned on (conversion van).

VortecFanatic57
05-04-2014, 10:06 PM
Finally did the upgrade! Bought the DR44 145amp with the 4-pin connector. I also upgraded my wiring to the "big 3" which consists of 1 gauge cables. I did not remove the factory positive and ground cables I simply just just added the new cables under the existing ones. Turned on the truck and voltage is at a steady 14.7 volts, dips to about 14.0 with A/C on high, hid headlights and fog lights on and does not drop any further parked at a red light on drive. Truck seems to run smoother too. I will post pics of the upgrade tomorrow... Overall, highly impressed with the upgrade and recommend it to anyone who needs more juice! Thank guys!