New Alternator To Avoid

If you ever go to the shop again ask
a) at what voltage ?
b) at what rpm ?
If they look at you like you have four eyes, its not worth arguing over. It is something they ought to know and will make a difference in the max amperage as that varies with both.

However the bottom line is the fact that you (12many) were sold something that doesn't work as advertised. See if you can get your money back.

7024 is a "Lester number" used by many aftermarket places as sortof an industry standard.
WAI Global owns Transpo, a MAJOR supplier of alternator and starter repair parts. :( Their stuff ends up in a lot of rebuilt and repaired alternators and your experience on confirms my impression that the quality is not there. :(

I don't recommend using revised squarebacks because the rotors draw more power than the regular squarebacks. It has been my experience that additional current may be more than the regulators made for the earlier alternators can handle. The other issue is that with increased current draw, any resistance in the path to the regulator causes a greater votlage drop. I can't prove the first, but the second is definately so.
Some good info, thanks. The only reason I went with this “all new” alternator was it showed as being a 78 amp. I have about a calculated combined load of 45 amps and figured the 78 rating for my van would be about right where I needed to be without resorting to 100 amp+ versions. I had a 100 amp upgraded early style (had the big diodes etc) version years ago for a big stereo system but the alt failed so went back to the 60 amp standards and eased up on the sound system (this was prior to electric pumps, fans etc where the load was much lower) Now I need the increased amperage, more so down low for in town etc with that 45 amp load. Just gonna have to bite the bullet and upgrade to something else, and rework/modify brackets and whatever needed rewiring.