To start off (after a disaster with my generator and cut out)..Less than a month ago, I bought the alternator that directly replaces the generator (5119alt6). It has the pinion gear already attached. The part fit on like a dream. (little tight)

However, when i run the car the alternator makes "a heavy turning sound", really loud. and the alternator seems to be putting a heavy strain on the engine(which is about 5months back from a full rebuilt). Especially when shifting in high gear, the strain of the alternator would "shutter" the engine.

I went to my local club. They suggested add a extra gasket to the cast iron piece that holds the alternator. That was not easy, took a lot of effort to get bolts lined up.

It helped little, but the engine is still straining, and the noise of "the alternator turning" is not as loud, but still present and is about equal decibel as the engine itself.

Did i get a dud? or am i missing something how this alternator was supposed to be installed?
Thanks

Robert, it might be time to use some bearing blue on the alternator gear to check the gear mesh. If it is set too deply, you may find polished areas on the top of the gear teeth or on the base of the teeth on the cam gear. This will tell you if the gears are binding. Your new gasket having some effect is a good indication of this.

Hope this helps.
Allan from down under.