HELP? Alternator pulley is too long after Putting in a new one?

After I changed my Alternator out (Squealing) the belt started coming apart, I figured bad belt, but as I put a new one on, I see that the belt is on the inner side of the A-Pulley and rubbing on the Alternator. It bolted right on, so I don't think wrong Alternator. Is it a rebuilt though. Any thoughts?

 

Had to change to get email notifications.

 

It sounds like you have not installed it correctly. Post a picture so we can see what you are saying.

 

Not to sound unappreciative, but it's kind of idiot proof, but then again...... I installed another belt and it ate it because it was walking up the downstream Idler, which I just installed last week. So in looking at it I had put the bushing on the inside, so I took it off and swapped to the outside, still just over the edge of the idler (The belt was). So I had another idler for another day in my shop and put the new one in, bushing outside, and it is better, but is still just off the idler an RCH or two. It appears to track on the alternator correctly, but I'm concerned it may walk again. I spend a bit of time in the non metropolitan areas and in the woods, so any advice is appreciated. Here's a pic of the alternator and idler while the engine is idling. I took for a testie and no weird noises.

 

So, you had to customize one of the pulleys to align the belt? You didn't have a problem with belt alignment after the idler pulley installment? You don't know if the new alt matched the old alt? Maybe the pulley in the new alt was incorrectly installed? I'd be concerned 'cause in the long run, you may have premature bearing failure.

 

Is this an OEM replacement? I replaced the belt tensioner on truck and the pulley was misaligned by about 1/16. The belt was riding on the edge of the pulley. I took it off right away.

 

The alternator may be misaligned some, but trying to convince the boys at O'Reilly's may be a task, and the PITA that it is to change as well. It seems to be doing okay. Perhaps the bushing does go on the outside? The OEM idlers don't have bushings.

 

What did you put on in it's place? OEM?

 

At first I bought a Gates tensioner. I just reinstalled the old one after I realized I could just replace the pulley. I still have the tensioner since I missed the return deadline. Not sure what to do with it.

 

From the photo it looks like the bushing used on the inner side of the pulley is too thick.

 

If you still have the original pulley that came off your original tensioner you'll notice that it won't match the gates spacing. I wouldn't recommend the gates tensioner or bare pulley they don't have the same spacing as the oem Toyota.

 

Just had this happen and lost a bnip belt