Alternators can be rebuilt. YMMV of course, but I rebuilt the Bosch alternator on my old Mk1 VW Rabbit several times (brush would wear down) with no issues.
I replaced it with a Duralast Gold. After replacing the issue still existed so I replaced the alternator with an OEM Bosch remanufactured unit.
I replaced the alternator on my Windstar last month. Disconnect the wires, remove 3 bolts and lift it out. Takes like 10 minutes or less.
My Lucas 18ACR (43 Amp) died shortly after I installed a big electric fan (I moved to Texas and felt it was a good idea), so decided to go with a higher output Bosch. I got tired of searching the parts shops (Advance Auto etc.) for a reconditioned Bosch that might or might not fit... In the end, I took my Lucas to an alternator shop and asked for a Bosch that would fit without modifications.
New Bosch installed Thanks for your help. It was in fact the alternator. Had a NEW Bosch installed by M&M Auto/Cycle in Jersey . Mikes the man when it comes to TDI service.
Order a 6 groove 120A alt though. It's an easy no brainer update. The car benefits under heavy loads and startup. Rainy days when the lights, wipers, a/c, heater, seat warmers, etc are all running will be worry free and your battery will charge back up with less drive time.
Voltage regulator is built into the alternator. If you're seeing 14.5 V with the engine running it's as good as it is going to get.
I am pretty sure that the 120A-Vr is much like all of the later Bosch alts with internal cooling. I just took my 120A 1.8t one apart and it is a PITA.
I figured alternator, so took it to Autozone to scan and everything passed. Then took it to Meineke for them to check and they told me alternator was bad and replaced it. Well my interior lights were still flickering so I took it back and they say seems like the one they installed was defective, so they replace it again with an OEM Bosch and also print me a printout of a bulletin stating that under load lights may flicker and there is no solution.
I had one during college... For a V6 it wasn't particularly quick and handled a lot bigger than it was. In three years it ate five alternators and the intake runner control box was notorious for failing (killing what little power it had).
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