Adding winch to 93 YJ with stock bumper

[bcemrich]

Hello, Well I finally got around to installing a winch. I still need to spool on the synthetic rope. I decided to add a disconnect switch to the winch. I don't have a/c and what I thought the mount for a/c compressor looked like an easy spot for a disconnect switch that didn't require any new holes. I would like to upgrade the battery and the alternator. I did a no-load test of the winch and it was drawing 73 amps and my alternator was putting out about 53 amps. I purchased a 135 amp alternator but want to get a better understanding of the remote voltage regulator among other things. I don't want to burn up anything. Also it looks like the alternator B+ goes into the fuse block in front of the battery then to the battery on the left side. I replaced my starter cable while I was removing crispy 33 year old battery cables but I haven't changed the one from the battery positive to the fuse block. I will go up a size when I replace it.

Has anyone upgraded to the 135 amp alternator? I would love to hear how it went. Thanks.
Brian

 

[bcemrich]

The existing cable from the fuse box to battery pos. That is where I measured the 53 amps with a clamp on ammeter while running the winch.

 

[bcemrich]

The battery that came with the jeep when I purchased it is very tired so I will be replacing it this week. The CCA rating of the existing group 58 battery is 550 amps and Smittybilt says the minimum CCA rating should be 650 CCA. Looking at the different groups I think I will go with a Group 48. The positive is on the inboard side but I'm already replacing all the cables. The group 48 is about 0.6 inches taller than the OEM group 58 so having the positive on the inboard side will provide more room to hood. Has anyone run a group 48?

 

[bcemrich]

I decided to go with the Optima Yellow Top 34/78. I will post a pic of the final install.

 

[bcemrich]

With the new winch forward, I decided to add a receiver hitch to provide a rear recovery point. I dropped the fuel tank in the process and went ahead and replaced the leaf spring shackle bushings with OME urethane bushings. I don't know the service history of the jeep but I was surprised how flexible the old bushings were. I also replaced the steering damper and really noticed a difference; the old damper wasn't totally blown but you can see where it was leaking. This week I will finally get around to winding up the synthetic winch line under load!
Cheers! Brian