[Merv and Sharon]

I think that you have it Dave. I am no mechanic but I am advised that belt tightness is the key. Certainly not as tight as a conventional fan belt. These Gilmer drives create such traction that they can put stress on the alternator and its mounts. Also, if they (the Gilmer setup) are of poor quality they may not have been properly balanced and the bolt holes to the waterpump and crank maynot even be centred (some of mine weren't). Others can advise more.

There are several guides on this on the 'net, but be aware that the belt tightens as it warms up. The pressure on the front and rear bearings on 2G alternators are considerable, but maybe less with 3G/similar ones. I had a wiring burnout but this may have been due to another source. The brushes were also worn. I am getting some ally pulleys made and balanced. Will misss that noise, however! (but not the burning alternator smell).

Hope this helps,

Merv