It's usually just the brushes. On a Bosch unit, under $25 gets you the voltage regulator with the brushes, and we're talking 2 screws and 5 minutes to swap it out...without even removing the alternator. If you want to replace the bearings, less than $20 gets you both bearings and takes about 15 minutes with the alternator off the car. Life expectancy? My 1.6 diesel alternator went dead at 1:00 a.m. about an hour north of Las Vegas. 289,000 miles at the time.
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NEW: Bosch dist. cap
I have the Bosch Icon wipers. Same set I put on in Feb of this year and still going strong.
I've been using bosch FD5POR aka rs2 plugs. I'm quite pleased with them.
I got the bosch alternator pulley kit from ECS that seems pretty complete so am hoping I am good on that front: As to why I have to replace the pulley, the pulley on these alternators is clutched and said clutch goes bad. Symptom being a perfectly fine charging voltage but a chattery sound tied to the alternator light flashing on the cluster. Did a ton of research on here trying to diagnose and this is what I've come-up with as a starting point.
After testing, 14.8 v at the starter when cranking is better than the .7 volt drop before! and now there's no battery drain!
Brand new timing belt (run idling) Turbo K03-001 (brand new run just idling) Bosch 386CC injectors (brand new run just idling) MS2 V3.56 MANAGEMENT EQUIPMENT MEGASQUIRT OEM clutch kit 2 1/2 intercooler piping with front mount 3\u201d turbo back exhaust (side exit) Audi TT conversion Fron Brake kit rear disk brake conversion kit Audi TT Master cylinder , brake booster, and brake lines Full mk4 tranny swap with Hidraulic Clutch Eurospec fuel pressure regulator K&N Monster Filter NGK BKR7 Spark plugs Dinomax exhaust 3\u201dx3\u201d HKS SSQV Blowoff N75 Race valve
I charged the battery and started the car, then drove to Autozone where their tester said that the voltage regulator was bad. Installation took less than an hour. Once up and running everything worked well and I even took it back to Autozone and had it rechecked.
Just a cautionary note for whatever you want to do with it. These will likely not be Bosch quality; could be Vespark from Taiwan or something from China.
My newly remanufactured Bosch 120amp alternator was extremely hot last night on the end of a 500 mile trip. Alt light never came on, all electricals were good, but there was a burning smell form the vents that seemed to be coming form the alternator's location in the engine bay. I touched the casing and it was very hot. Now this morning the battery is stone cold dead.
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