[Stdyhand]

I just put a 3G alternator on but the original pulley that was on the alternator can't be used.

Two problems.

1. The belt isn't large enough. It is about 1-2 inches too short. Even with the tensioner maxed out it can't be slipped on.

2. The original pulley looks like it is slightly too far back for the belt to line up. I was thinking a washer behind the pulley might line it up.

Can I use the OLD pulley from the 2G which would act like an overdrive pulley since it is smaller and would cause the alternator to spin faster?

Would this be dangerous and cause the alternator to put out too much power?

I do have a 175 amp mega fuse less than 6 inches from the positive terminal on the solenoid. I am also using 4 gauge wire.

I read the alternator is only a source of power and isn't actually putting out except what the car is pulling so would it matter if the alternator is spinning faster?

[Dap1991]

ive heard of a few people swapping the old pulleys over and using washers, they usually do it to get a little more juice out of the alternator since a smaller pulley wil spin faster.

[Stdyhand]

I may try it out. The car isn't going to be seeing any real high RPM right now so I shouldn't have to worry about over reving it. This was a Taurus 3G I got from a J/Y. I just reclocked it and I'll be getting a new one in the near future with a lifetime warranty so I should be able to get the correct size pulley then.

[91cobra5.0]

if the belt is that short a smaller pulley isnt probly gona help but there should be no issue putting a washer behind it as long as it makes the belt line up

as far as spinning it to fast just watch your guage and just make sure you arent running a crazy high voltage

[Dap1991]

did the belt fit before?? Did you delete your a/c or smog or something? I cant see how the belt would be that much shorter unless the alt. is in a different position or your routinh it incorrectly perhaps?

[Stdyhand]

The previous owner deleted the A/C and the smog pump and instead of using a delete kit to keep using the stock belt, they just went with a shorter belt. I left it like this since everything was working fine. However, the belt was kind of on the tight side, but it could be gotten on. The new pulley however is larger and puts it over the limit for the length of the belt. The old pulley is like 1.83" and the new is about 2.41".

There is about a 1/2 difference in the width of the pulleys. I could get a longer belt by 1" or so but if the smaller pulley will work then I'd just assume do that for now.