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Message: [QUOTE="DcMoore, post: 1000572, member: 382"] After numerous alternators I finally looked into the main issue a little more. After some searching I found that the small cased 6g alternators that are in the 7.3 Super Dutys go out because they do not cool themselves properly. Also, the 7.3's factory alternator's output is 110amps and the 6.0s large case alternator puts out 140amps. I went to O'Reillys and bought an alternator for a 05 6.0. I found some people online that sell a "kit" to install them on a 7.3 but it is just three washers. I ended grinding the alternator bracket so it would fit. If you don't grind the bracket down the rotor will rub on the stator and you'll be back at square one with a bad alternator. Alternator comparison [ATTACH=full]136353[/ATTACH] You have to grind the front and back. [ATTACH=full]136354[/ATTACH] [ATTACH=full]136355[/ATTACH] Ground bracket with the alternator in place. [ATTACH=full]136356[/ATTACH] Finished product [ATTACH=full]136357[/ATTACH] I read somewhere that you need to clock the new alternator but I think it looks way better without the wires going into the top of the alternator. I also read that you have to change the pulleys on the new alternator but mine was an exact match to the new one. [/QUOTE]

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