Well i wired up a efan and with headlights on too my voltage goes to high 12's. Running a ltx8 to control fan meth water pump thats about all aftermarket. Im running the villager fan. I have an s4 with a dual knight sports pulley so id rater try the s5 alternator so i dont need new pulley for a s6. Anyone have around the same setup with the s5 working ok. Dont want to try and waste money if it wont be enough and have to go s6 anyway. I called a local alternator guy and as soon as i said mazda he just said he didnt want to build it up for me. Any help would be great.

 

The S5 alternator creates about 10 more amps than the S4 counterpart. The link below is a place used by a fellow member who had the amp output on his S4 increased by about two fold.

http://irperformance.com/

 

FD alternator puts out about 90 and more(100 -120 depending).It is plug and play on an S5 or you can install it on an s4 if you have the S5/s6 Pigtail for the alternator.slight wiring to do.
I have an FD alt on my s4 and it is going strong.
as far as an EFAN..try a Mercury Villager fan(1995-98) they draw less amperage and fit a KOYO rad like a Glove.hardly any Cutting.comes with a shroud..it is also a 2 speed.Blows great.(about 3800 CFM).

 

you already know about the FD alternator and how it require a new connector and pulley.

another option would be to find an alternator shop and have them rewind it. i know of people that have had their S4 alternator rewound for ~120A. usually a reasonable price too.

 

seems like it would be cheaper to just get an FD alt and have your current pulley milled out a bit, then to have an alt rewound.

 

I know all the options thanks alot though. Noone local want to touch my alternator. I was kind of hoping someone else had a microtech and the villaiger fan and had the problem i am and could say the ten extra amps of the s5 would suffice. I guess going s6 and getting a new pulley would be the smarter approach. No point in getting s5 and still having issues when my fan comes on at idle. Wish i just had a functional bac.

 

I already have the villaiger fan. Thats when my problems started. As stated above im using my ltx-8 to control it. Other than those two aftermarket electrical devices and my meth/water pump its all stock. No bumpy bumy radio crap. It only starts dying with headlights and fan both on. During the day im gold, but at night at a light my fan will kick on and almost kill car and afr's go lean as hell.

 

Get some angle steel and a taurus alt.
https://www.rx7club.com/2nd-generation-specific-1986-1992-17/130-amp-alternator-sweetness-785082/

My first bracket broke because it was ill made. Jackhild's has not though. I have since remade it by cutting the .25 inch or was it .125 inch angle steel and welding it together. Except for idling sometimes. I get 13.9vdc-14.1vdc. When it does drop it drops to 12.8vdc-13vdc. Oh yeah you'll also need to find a pulley that's 3inch diameter. I think it is.. Anyway the details are inside the above thread.

Also: https://www.rx7club.com/2nd-generation-specific-1986-1992-17/ford-tempo-escort-alternator-write-up-not-56k-friendly-827200/

 

The S5 is not enough, you will still have problems. The FD alts are harder to find in running shape.

My Taurus alt is still going strong and my bracket is still strong and straight: 130 amps is enough. Taurus alt is cheap to get even if you buy a new one.

 

Well i called the main three parts places we deal with at work and got a fd alt. for 105 lifetime warranty. Now i need to find a pulley and pigtail