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Ok, After extensive moifications, I finally got a serp belt on my truck.
I removed the smog pump, and have seen many trucks just get a shorter belt. The 94.5 fit, but was a little loose. I installed the smaller pulley for the 200 amp alternator that came with it 2 years ago and ended up using a 93.5 belt. It fit perfectly. There is a problem however. The tensioner pulley looks wrong, and what I mean by that is... the belt is sitting mabye 1/8th of an inch closer to the engine than it used to. I mean I see 1/8th of rust or wear on the pulley that is where the belt used to sit. It also looks like the belt is moving in and out a little bit. Nothing too scary though and the belt is still on the pulley. However when the AC cycles on the belts jumps and looks like it is going to fall of and has fallen off many times if I start with the ac on. I'm kinda stumped. There is no problem with the Ac I have checked everything.
I am wondering if the shorter belt is making this happen, or mabye the smaller alt pulley.
Have you carefully looked at the alignment of all the pulleys from the side of the engine. Since you changed the alternator pulley and water pump be sure that all pulleys are exactly aligned with each other.
I checked it out, and it is firm as stone. Dosen't move side to side. The alternator does look like ti is a hair closer to the engine though. No way to adjust it. I wonder if I could shim it up.
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