I am one who has upgraded my stock AAZ alternator pulley to the new ratcheting design... and based on the number of times I see it do its magic I feel much much better about the survival chances of my crank sprocket.  You can actually hear the alternator try to overdrive the crank but the pulley releases and the belt stays smooth.

The new pulley is exactly the same size and offset as the original and will thread right on *but* you need a special tool set (available from Metalnerd among others) to tighten it down, and the old style alternator shaft won't take the new locking sleeve... I drilled and tapped the end of the old shaft to take an extra bolt instead.

Been meaning to post a HOW-TO and took pictures but never got around to it... you're the second guy that's brought this up recently so maybe I need to get off my butt.

Some pictures that will (eventually) get into the HOW-TO:

materials and supplies:



Tapping for the locking bolt:



I pulled the old pulley off, wrapped the alternator tighter than an Egyptian mummy in about 100 layers of saran warp, and then put the old pulley back on to drill and tap.  The shaft on mine cleverly had a dimple at the exact centre. Two bolts (seen on the left side of the first picture) fit down thru the housing into the fan to keep the shaft from turning.

Closeup of the finished product:




I got my pulley from my usual jobber... VW # 028 903 119 AA.  

$110 hard-earned Canadian dollars  :shock: and in my mind worth every penny every time I hear it release and save my crank.  :wink:

Hey Sam... de nada.

In terms of the different parts (and their very different prices) when I did my initial investigation I couldn't convince myself that the cheaper of the two had exactly the same offset, diameter, shaft size and thread pitch etc... I believe it's for the later TDIs, which I believe use a different style of alternator.  The AA part is listed as a direct substitution in my ETKA.

Since I couldn't find an easy way to convince my suppliers to let me return the cheaper version if it didn't fit I bellied up for the one I knew would work.

So, if you can figure out a way to check this again (or perhaps someone else has tried ?) you'll resolve yet another mystery of the universe and make it much more affordable for all AAZ owners to perform this pretty-darn-useful upgrade.   :wink:

The dealer even loaned me the spline tool.

Hang on to that dealer son.... he/she is a gem.  Every one I talked to didn't even know the pulley existed, let alone that a special spline tool was required... let alone lend me the tool.   :wink:

i changed the whole bracket and fitted the complete alt, worthwhile upgrade IMO!!

GEE-BEE.. thanks for the info! I just realized I have messed it all up!

Both of my alternators are 90 amps and my car has aircon. After reading out Vince post I also ordered the 028 6 grove pulley.. but my alternators are 90 amps which I just checked now..

So is there any way I can make this work on a 90 amp alternator? or if I find a 120 amp alternator will I be able to fit that into my car and use the same belt rest of the pulleys?

Thanks!   

Okay I installed it on the 90 amp Bosch alternator. And original pulleys on both the generators were 6 groves in spite of being 90 amp.

The valeo alternator does not take the pulley part# 028 903 119 AA (bosch part# 1 127 011 846 and 1 126 601 565) 6 groves. the shaft is too small in length.

And on the Bosch one the washer behind the 24mm nut has to go behind the new pulley 028 903 119 AA pulley to attain the correct offset.

I must say this thing works wonder!! The belt is so smooth now and doesn't jump any more.. finally that irritating noise is gone.

Thanks guys for all the help; couldn't have done with you all!

Best price for non-China ( ina )

Ebay item #200350268420

75.00 free shipping

I let Al know I would post this , So ask for the Forum price.....

He also has a link that explains how these things work and reduce stress on the drive belt system.

You will not need the spacer behind the pulley.....


GB