Alternator nightmare...

The darn alternator keeps dropping despite repeated attempts to tighten so i decided to strip the bracket assembly in the hope of sourcing the later "toothed bracket" and also the pulley as it was slipping too…

I found the pulley absolutely full of black powder… upon undoing the nut and taking it off it seems that its been spinning on the spindle / shaft of the alternator because the groove which sits over the woodfuff key has been completely gound away. Its cut a nice deep groove into the alternator spindle aswell. The other components look buggered aswell such as the spacing washers also which should have the notch for the woodruff key (not sure of the exact names as the Haynes manual still hasnt arrived!)

Then I dropped the halfmoon woodruff key and lost it - joys of a gravel driveway DOH!

Ayone know what might have caused it / where I can get replacement pulley and spacer components from?

Oh, and how do you guys hold the large flat hex-washer still when your tightening the final nut to fit the pulley back on, as the nose of the water pump pliers are too wide to fit in the gap to grap it??

Sorry for the long post, its been a long day!

Mike

hope the new one works

Been working on the motor all day today until 7pm, got loads done, although its taken til now to defrost my hands sufficiently to be able to type!

MASSIVE thanks for the help with the alternator mate, its spot on! Much appreciated mate!! I owe you one…

I'll have to pop over to see you in the Gti once its all finished, I'm away for most of January so will crack on when I'm back and make the trip over when its done.

Like I said I have no need for it now because its different from the 16v