[MrClean]

Did you grease the but/washer connection area so as not to get a false reading. Did you tap the pulley on a bit to ensure that it was truly seated? Sounds like it didn't seat all the way and you just seated it the rest of the way.

Listen, I am not saying I'm any better than you and YOU have got me worried about MY install. But it could be as simple as that, you didn't get it seated all the way and the pulley was just allowed to vary path a bit. Not saying you have a bunch of chewed up primary output shaft splines, just that the front pulley/belt alignment was off and squealing. There, now we both feel better. When you were re-tightening your pulley did you notice a bunch of chewed up aluminium dust in the covers? If not, you're probably AOK with a nut that is now more secure. One thing for sure, if the tabs on the washer were bent over the nut, your nut didn't loosen, your pulley seated further in.