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Alternator mounting issues

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Old Dec 9, 2015 | 10:33 PM
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Default Alternator mounting issues

I am replacing my alternator, the engine is a ZZ4 with lots of dress up parts. My issue is that the old alternator had an aluminum pulley installed, slightly larger diameter than the one on the new alternator. Also the belt 25-7541 was always too loose for my liking. The mounting arm will not adjust any further and the alternator is all the way to the end of the slide mount. My questions;

How in the heck can I get the old aluminum pulley off the alternator and on to the new alternator?

Can I get a slightly smaller belt so I can cinch it tight with the alternator mounts?
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Old Dec 9, 2015 | 11:26 PM
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Originally Posted by DSchaefe
I am replacing my alternator, the engine is a ZZ4 with lots of dress up parts. My issue is that the old alternator had an aluminum pulley installed, slightly larger diameter than the one on the new alternator. Also the belt 25-7541 was always too loose for my liking. The mounting arm will not adjust any further and the alternator is all the way to the end of the slide mount. My questions;

How in the heck can I get the old aluminum pulley off the alternator and on to the new alternator?

Can I get a slightly smaller belt so I can cinch it tight with the alternator mounts?
impact wrench only otherwise you could bend the fan fins and the unit will not cool as efficiently

of course get a smaller belt
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Old Dec 10, 2015 | 07:35 PM
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Thank you, got a smaller belt gave up on the pulley swap.
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Old Dec 10, 2015 | 09:54 PM
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Originally Posted by DSchaefe
Thank you, got a smaller belt gave up on the pulley swap.

or try cracking the nut while the belt is on tight, it might give
besides a smaller pulley will prolly get you in the alt sweet spot sooner

Last edited by slickfx3; Dec 10, 2015 at 09:56 PM.
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Old Dec 11, 2015 | 11:57 AM
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Go to your local alternator/starter rebuild shop and have them swap the pulleys. They'll probably do it while you wait. Advance auto or equal might do it for you as well.
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Old Jul 17, 2020 | 01:22 PM
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My 97 C5 in drive i'm getting grumbling vibrations only at idle stopped in drive. Sounds like coming from at driver seat or just behind driver seat area. Mine is Automatic and has 89k miles. I wonder on mine alternator pulley causing this issue.
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