I've finally got around to upgrading to a H/O alt for my sound system, so I got a 250 amp Brand X with a regulator bypass to bump my charging up to 14.8.

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The issue you will run into if you go this route is the plug sticks out and hits the power steering pump bracket which you can see in this video (not my video) https://www.youtube.com/watch?v=fW6GBgoMkq0&t=353s

So to solve this issue instead of grinding down the bracket like they did, I decided to trim down the connector and direct solder the leads.

As you can see the alternator pulley is significantly smaller so I got 2 smaller serpentine belts.

Here is What Rock Auto recommends for a stock replacement the ACDELCO 6k882

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Here's 1 size shorter as per their online catalog (6K878)

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And the next size down (6K876)

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The Issue I'm running into is when I installed the shorter belt, I am getting a pulley squealing sound I'm assuming slippage. My charging voltage goes from 12.2 (not charging) for the first 10 or 15 seconds, to 15 volts where it should be then up to 16/17 volts and bounces around. I'm assuming because of slippage or an issue with the tensioner.

I need some help from someone to diagnose the issue, is there any reason why these belts shouldn't work if they are the same amount of ribs as stock just a bit shorter? Or is it possible the tensioner is going out with the new belt loaded on?

It seems like the regulator/wiring is ok, because when the belt finally catches on it was hovering perfectly at the set voltage 14.8.

I've done the big 4 upgrade to 1/0 gauge for grounds to the body/engine/frame and alternator to battery.

I also just got a brand new interstate 24F AGM which is resting at 12.6 when I tested it. Any ideas?

maybe tensioner, but having that 14.8v cold voltage is kind of high.

im no expert, but contact your alternator company. thye should have some basic troubleshooting.

or return your alternator for another brand? im using mechman on the v6.
are you running the shortest belt? 87- 87.5 ?

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Thanks for the response, I may have to get it swapped back to the stock regulator. The reason I wanted to go to 14.8 is so I can run lithium to support 6k.

Did you have to get a shorter belt for your Mechman?

yes, shorter belt.

i found the gates green heavy duty belt for my application.

i also changed my tensioner 2 years ago, it was fine with the original one. so i probably didnt need to change it out.

Not to sway from OP but do you have more info on this? Contemplating upgrading to HO alt and running a new wire off battery to power a new fuse block for future accessories/lights.

Get the Gates FleetRunner belts.

I had an AC Delco belt and it squeaked horribly right out of the box. The Gates Fleetrunner hasn't made a squeak in 3K miles.