1997 Ford F-150 - Alternator issues

Did you compare the old alternator and the new one for exact size, fit and pulley size? Clearly something is different. Since only you have the truck and the parts in front of you, only you can make that determination.

If I have to take a blind stab at it… the pulley is a different size on the new alternator than the old one. OR, you aren’t moving the tensioner enough mount the belt.