Humvee alternator help

Humvee modifications, sugestions, and ideas, official MWO's and unofficial field mods

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Humvee alternator help

Post by nshan818 » Sun Feb 19, 2023 7:17 am

Hey all

Just got my Humvee from govplanet looks like it’s missing the alternator and the wires may be cut please see photos attached. What’s the best way to go about getting this fixed

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Re: Humvee alternator help

Post by 87humvee » Wed Mar 01, 2023 10:08 pm

Two options

1- replace entire engine harness you will have new ends ( expensive endeavor)

2- just use good connector and join new ends to existing cut wires.

Identify the 3 connection if that’s still have their silver tags. These will connect to your voltage regulator

Mark Rozak
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Re: Humvee alternator help

Post by Mark Rozak » Thu Mar 02, 2023 9:49 pm

From your pictures, it appears it was a 60Amp Alternator with 6.5 NA (non turbo) engine with V belts.

60 AMP Alternator is used on M35A2, M35A3, M818, M923, M923A1, M988, M151, M151A2, M931, M813, M936, M923A2.

Electronic parts, and service manuals are available from a couple sources.

Pulley V-Belt 60 Amp 12339395 3020-01-198-0633
60 Amp Alternator 10929868 2920-00-909-2483

Pivot Bolt setup 2 versions
One Long Pivot bolt
Long Pivot bolt 7/16-20 x 9.75 B1821BH044F975N 5305-01-429-9149
Nut plain for Long Pivot bolt 7/16-20 9417028 5310-01-457-3171
Two Pivot Bolts
Pivot bolt rear 7/16-14 x 2 MS35764-853 5306-01-276-0848
Pivot bolt front 7/16-14 x 1.5 B1821BH044C150N 5305-00-071-2055
Spacer (pivot bolt) keeps housing from vibrating and breaking a mounting ear
Belt adjust top lock bolt 3/8-16 x 1 B1821BH038C100N 5305-00-068-0510

Wiring had 3 lugs and one waterproof military connector
Image60A Alternator connections

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Re: Humvee alternator help

Post by GPW43 » Fri Mar 17, 2023 10:07 pm

I will share a picture of mine. I had to modify a truck 60a UNIT to have a second big lug for the M998 but they are the same alternator just make sure you get a three lug unit. The lug with the RED wire I added as it was missing. You need some wires (heavy duty battery cables with lugs) and shrink wraps. Cut the thick wires at an angle and mate them that way. The tape over the solder area to build it up then shrink wrap it.

Wire cut solder.gif
Wire cut solder.gif (7.99 KiB) Viewed 48 times
GPW 43

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Re: Humvee alternator help

Post by milcommoguy » Sat Mar 18, 2023 2:31 pm

Good picture.
Not SOooo sure that's the best way to splice wires shown in the drawing. There are in-line "BUTT" style crimps for the gauge of wire shown. Then solder? Shrink sleeve always a good idea.

Should be easy as wire is only 6 or 8 ga Looks bigger with lots of insulation.

Whatever works I guess, CAMO
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