Is about experiences. I still haven’t got a failed regulator on my 74 Charger in 19 years.

The Bosch alt ( internal reg ) on my parents 75 Mercedes failed once in last 10 years or so.

Both cars being drivers.

What I meant is there is NO LOGICAL REASON to say it won’t fail just because is internal reg. Both can fail the same! But external is easier to test and replace.

Aside in case of emergency you can full field the alt to arrive home being external!

Not to mention an external regulator can be mounted in a less stressful environment. Seems Mopar put the regulator in the computer and stayed with external regulation.

New product. I have 90A low mount kits in stock but I haven't gotten them boxed up yet for sale. The 60A low mount kit is almost finished, I just need to get the straps powder coated. I'd recommend the 60A kit for your car, especially if you have a full size battery.

On a side note, if it goes open (no charging) or full fields (pull a field wire) I would suggest driving home with no charging as opposed to full fielding as max voltage wreakes havoc on the cars' systems cuz they dont like 15+ voltage.

you can drive with lights on ( including high beams ) and AC or heater at max speed and will release the load and voltage system. Just in case of maximun emergency because your home is 1 hour or so far and your batt could not hold the load. There is a solution or an option anyway being external, imposible to deal being internal.

$12 less at Rockauto.

( search by 7024N PN )

Amazing, they were going on $50 rate quite ago ( remanufactured )

kept searching at Rockauto and found:

PURE ENERGY 7546 $27.89
ACDELCO 3341006 $45.99
REMY 14256 $46.89

Everyone same 78 amps alt, remanufactured, but serpentine belt pulley. Is just about change the pulley and done.

( searched on 86 Charger turbo list )

I bet searching down some other models will get the same

So if we think on the BEST BANG OF THE BUCK as requested... IMHO this is the winner.


EDITING... all these alts are A HAIR WIDER than the stock due the wider stator ( reason why they put more output ). This could be a problem on BBs, but getting a longer belt ( just 1" or 2", can't recall ) is enough to sway the rear of alt from block, and trim a bit the rear spacer to keep the best belt aligment will make the job.

Being there done that

My next bid ( when life allows me to pay for this, on $200 rate ) will be the TuffStuff 8590DP alt

cast finish, 100 amperes double pulley.

Aaand will keep the stock 40 amps ammeter still with this alt. I trust on my Charging system.

I'll be honest Nacho, this is a tough call. At night, I'd do it with 37 - but with a higher output alt I don't know. I'm not sure even with everything on the voltage will stay under 15.

Daytime is different. I would definately prefer to run on battery for an hour. Ignition takes so little power - could even jumper the ballast if voltage got really low.

Maybe Tuffstuff has become better but I'm not impressed with the one I bought. It had a squeak from the day I bought it. Sent it back forthem to fix and they said it was fine and they returned it to me. Still squeaked. Took it off before a long trip several years ago because I didn't fully trust it.

Fast forward to last year. Needed to replace the alternator quick so reinstalled the Tuffstuff. Squeak only was getting worse. Finally took it off. A little detective work and found the squeak was coming from the brushes???!!!
Yup. Something was on the slip ring that is sticking or grabbing the carbon.

1.

yes a tough call, but as I told as extreme emergency. You can do it or not, but still have the option. Internal regulator not even the option.


2.

Have got diff feedbacks about tuffstuff alts but latelly they seems to get better.

Which one you got ? I could buy that one from you and maybe fix it ? LOL

BTW, thanks for everyone's responses. I still have some things to look into, but you've given me some good ideas on what else can be done.