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If you are not interested in placing a 200 amp, consider purchasing a GM 24 V alternator, (which is easily sourced and easily rebuilt), and make custom brackets and hook it up to your unit. There is no reason that you must use stock military items. Given that you wish to swap out a 400 amp...

I think replacing a 400 amp with a 60 amp is way off the RADAR. It is a serious downgrade that makes no sense. If it is a money issue, save up the money and purchase a proper replacement, and then sell the 400 amp unit to recoup some cash. IMHO

Just borrow a Diesel tach and measure true ROM at idle. Then again at 2000 ROM. Then again at 3000 RPM. Compare to RPM on the alternator driven unit. Then divide the alternator driven ROM result by the appropriate number to get the true RPM.

Yeah, you’re correct Steve. My point is the conversation has gone full circle. He needs to identify the “true” RPM and then confirm if there is a problem or if it is his perception that he has a loud engine.

Guys, the foundation here is the differential gearing. Ones the OP determines the gearing, he will have an answer, re.: is the tranny slipping or not properly shifting and locking up. Alternator pulley size is a non-issue. Action has clearly pointed out the RPM sensor on the crank.

You may already know this… Fast and easy differential check. Chain or chock vehicle securely. Jack up front end. Put transfer case and tranny into neutral and use secure jackstands to maintain safety. Mark a wheel and mark the drive shaft in crayon or chalk with a single line. Spin a wheel and...