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Old 05-28-2016, 11:56 PM   #1 (permalink)
Z71Hobbs
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Alternator Install - 1996 K1500

Alright, so I added a few accessories to my truck, and I noticed that the alternator wasn't quite keeping up. The truck has around 138,000 with what I believe to be the original OEM alternator. The truck has all of the original style items on the serpentine belt routing (ac compressor, vacuum pump..etc.)

So, I did some digging on alternator updgrades and found quite a bit of conflicting information. The end result was that for this year truck, upgrading to an AD244 style alternator in lieu of the CS144 alternator was my best option. Additionally, based on my limited research, the AD244 alternator doesn't seem to suffer from CS144 bearing failures that are known to exist.

So, I went down to my friendly neighborhood NAPA and spent some time and ultimately settled on an alternator from a 2001 6.6L Duramax. It is NAPA part No. 213-4807, which is a rebuilt alternator. This is the 130 amp option, which is likely more than I should ever need. It was around 190 bucks or so, plus a $29 core. Also comes with a limited lifetime warranty, which I like the sound of.

I have attached some photos of the alternators and the before/after install. This thread is not intended as a how-to, but I do hope that others get some use out of it. In all honesty, this is one of the simplest things that can be done to the truck.

The new alternator fits right into the same mounting as the old one, with one exception. The old alternator had a mounting point for a small bolt on the very bottom rear of the alternator (see photo with the plug detail). The new alternator did not have that mount, but based on the beefiness of the new alternator, I am not at all concerned. The only modification that I will need to do is to purchase a longer serpentine belt as the newer alternator pulley is located further towards the passenger side - my tensioner pulley is nearly completely maxed out and I believe to be out of range. I think that a 1-inch longer belt should suffice, but I will update with my findings sometime soon.

Attached Images
File Type: jpg 1. New Alt Bench.jpg (48.5 KB, 23 views)
File Type: jpg 2. New Alt Specs.jpg (57.1 KB, 21 views)
File Type: jpg 3. New Old Side by Side.jpg (42.4 KB, 22 views)
File Type: jpg 4. Plug Comparison.jpg (48.3 KB, 22 views)
File Type: jpg 5. Before Install.jpg (40.8 KB, 20 views)
File Type: jpg 6. After Install.jpg (34.5 KB, 25 views)
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1996 Chevrolet 1500 Z71, Vin S
Current Mods: Dual Relocated Gray PMDs to front bumper, turbo back diamond eye exhaust, K47 Airbox, FTB2.0 Stainless from Walking J, "F" intake swap, KOJO Tune.
Short Term Planned mods: New Mandrel Bent Crossover, oil cooler lines.
Long Term Planned mods: 4" RCX suspension lift with 305s.

Last edited by Z71Hobbs; 05-28-2016 at 11:59 PM.
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Old 05-29-2016, 11:03 AM   #2 (permalink)
57diesel
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Let us know what you end up with. An inch is a lot. If its too much and you can't get a 1/2 inch size you may be able to space up the AC on washers a bit. Just be sure to try and match the thickens of the washers pretty close, if they are off too far it kinda cocks the compressor sections and could end up leaking.

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95 Burb K25 3.73's CRASHED 250K miles, looks to have been rebuilt at least once, stock, bad rust, DE exhaust w/walker muffler, 8' western plow.
81 Buick Riviera GAVE AWAY with the infamous Olds 5.7 diesel possibly still going strong.
15 VW Golf wagon, TDI. Did the buyback on my 13 Jetta TDI wagon so it was basically a trade up.
96 Burb K25 3.42's SOLD at 340K miles, told it was all original, close race between engine wearing out or body completely rust out.

Last edited by 57diesel; 05-29-2016 at 11:04 AM.
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Old 05-29-2016, 11:46 AM   #3 (permalink)
alpacalips
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Awesome, thanks for taking the time to post pics! I, too read many mentions of the upgrade, but mostly vague info and without pictures. If my alternator takes a dump that's what I'll be putting in.
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Old 06-13-2016, 12:24 AM   #4 (permalink)
Z71Hobbs
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Alright, so I had some time to try a different belt. Ended up using an autozone DAYCO belt, part no. 5061020. I'm happier with the fitment.
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__________________
1996 Chevrolet 1500 Z71, Vin S
Current Mods: Dual Relocated Gray PMDs to front bumper, turbo back diamond eye exhaust, K47 Airbox, FTB2.0 Stainless from Walking J, "F" intake swap, KOJO Tune.
Short Term Planned mods: New Mandrel Bent Crossover, oil cooler lines.
Long Term Planned mods: 4" RCX suspension lift with 305s.
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Old 06-13-2016, 07:48 AM   #5 (permalink)
56pan
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Alternator Install.

Is there some way to determine the length of that serpentine belt from Autozone by the part no., Hobbs? I know it can be done with a V-belt. Did you measure your old one and ask the guy at Autozone for one an inch longer?
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'93 C2500 280,000 m.
60k on new AMG mil. surplus engine
Turbo with name that starts with A.
Straight pipe exh. (but it ain't that loud).
Peninsular intercooler
Boost, EGT, Glowshift intercooler in/out temp. 3 guage pod.
Rebuilt complete susp. with polyurethane bushings. (Bad idea).
20k on GM 4L80E rebuilt trans.
Dual thermostat/Duramax fan/high flow water pump.
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Old 06-13-2016, 08:14 AM   #6 (permalink)
Z71Hobbs
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I asked the guy at autozone for one that was 1" and 0.5" longer than stock. The DAYCO belt I settled on should be 102" long, based on Internet and the "1020" wording in the part number-but I did not actually measure it. The guy at autozone said a lot of belt manufacturers number their belt that way.
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1996 Chevrolet 1500 Z71, Vin S
Current Mods: Dual Relocated Gray PMDs to front bumper, turbo back diamond eye exhaust, K47 Airbox, FTB2.0 Stainless from Walking J, "F" intake swap, KOJO Tune.
Short Term Planned mods: New Mandrel Bent Crossover, oil cooler lines.
Long Term Planned mods: 4" RCX suspension lift with 305s.
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Old 06-13-2016, 12:51 PM   #7 (permalink)
56pan
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Alternator Install.

Thanks. Been looking for that information.
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'93 C2500 280,000 m.
60k on new AMG mil. surplus engine
Turbo with name that starts with A.
Straight pipe exh. (but it ain't that loud).
Peninsular intercooler
Boost, EGT, Glowshift intercooler in/out temp. 3 guage pod.
Rebuilt complete susp. with polyurethane bushings. (Bad idea).
20k on GM 4L80E rebuilt trans.
Dual thermostat/Duramax fan/high flow water pump.
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Old 06-13-2016, 04:59 PM   #8 (permalink)
JMJNet
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The Suburban Club Member

I posted about the belt length coded into the part no. a few times, I suspect it is in the FAQ.

Part No.: K061025 means K06 means 6 groove (K can be a number also) and 1020 means 102-5/8 inches nominal.
So if you need a belt shorter you would want to get 1015 (1 in shorter) or 1010 (appx 1.5 inches shorter), it has to have 6 groove so it should be K06 or 106, etc.
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PMD in Bumper
Leroy Diesel Flight System PMD
Leroy Diesel Oil Cooler Line
4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator
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Old 06-15-2016, 02:18 AM   #9 (permalink)
56pan
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Alternator Install.

Thanks JM.
__________________
'93 C2500 280,000 m.
60k on new AMG mil. surplus engine
Turbo with name that starts with A.
Straight pipe exh. (but it ain't that loud).
Peninsular intercooler
Boost, EGT, Glowshift intercooler in/out temp. 3 guage pod.
Rebuilt complete susp. with polyurethane bushings. (Bad idea).
20k on GM 4L80E rebuilt trans.
Dual thermostat/Duramax fan/high flow water pump.
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Old 06-25-2016, 12:10 PM   #10 (permalink)
Steve83
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This photo album may interest you: (the host may be slow)



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Dual Alternator Mod, Dorman FSD in grille, FFM raised, Opti-Lube, high idle switch, Curt Cl.V receiver, reverse sensors, hitching lights, 750W inverter, in-dash USB power, mini bed crane, all-on brights, Magnefines, revised 4WD actuator
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