HELP: Broke down in Panama... AAZ alternator pulley

[johnnygreenham]

So I haven't posted here for a while but that's because my wife and I moved into our van in the states and then decided to drive down to Panama. Broke down a few times and managed to fix everything without too much trouble.....until now.
We are on our way home and was on the mountain pass across to Bocas del Toro in the north west. Suddenly I lost my tach reading and my battery light came on. Pulled over and heard a slight whirling from the alternator. A quick check and the new-ish (18,000 miles) alternator clutch pulley has shit the bed. Just spinning both ways now and not turning the alternator at all. Drove it on the battery alone to a city called David about 100km away. Yay for mechanical diesels.

We have been here for two days and can not find a parts store that has German anything parts anywhere. I'm starting to think there is a conspiracy. Every parts store seems to be Asian/Japanese manufacturers only. I did not bring the original solid pulley or my tool to remove the clutch pulley which may end up being just as hard to find as the part itself. Will probably resort the the screwdriver in the alternator blade trick and cross my fingers. We left the casino this morning which we limped to last night and are now staying in a hostel where I can work on the van a little more. Haven't removed the alternator yet so not sure if driving the distance we did, on the busted pulley heated the shaft of the alternator up and damaged it or if the alternator has frozen. Seems like no one has Bosch alternators here either so swapping the alternator out may not as easy as I thought. If nothing else I got a chuckle at one store when there solution was ebay.eu

I'd be greatful for some part numbers of alternators that may fit like a 120Amp TDI one but it seems like german anything here is just not that popular and not sure if any modifications are required to fit another sized alternator..... BUT saying all this please post alternators that will work, especially larger amp alternators with a 'W' terminal.

I thought that this pulley was similar to a ford one used but ford parts are pretty hard to find here also. Trying to find Ford and VW dealers tomorrow as Sunday is a bust for most places in town.

Can people throw in some ideas or possible parts that may work. The shops did have a 7 grooved pulley from a Nissan which is 65.5mm diameter (10mm to large and I have no idea if the spines are the same or if the ID is similar. They seemed pretty excited when they found it and not so excited when I turned them down because it was so different.

These are the specs I have in my notes for the pulley. The engine is our beloved AAZ 1.9TD


The Specs for the pulley I have are are as follows.

Manufacturer VOLKSWAGEN
Number 028 903 119 AA
Description Freewheel Clutch, alternator
Outer Diameter [mm] 55
Width [mm] 40,3
Production Number
1220902

Cross numbers
FORD 1106734
FORD 1469755
FORD 6M2110344BA
FORD 95VW10344FA
HK G009Z
INA 535000110
SEAT 028903119AA
SEAT 028903119P
SKF VKM03106
TRIPLE FIVE 0380340
TRIPLE FIVE 139281
TRIPLE FIVE 335170
TRIPLE FIVE MBI28310
TRIPLE FIVE PBT8566
TRIPLE FIVE RKT2056
TRIPLE FIVE TA20511
TRIPLE FIVE Y2000
VOLKSWAGEN 028903119AA
VOLKSWAGEN 028903119AQ
VOLKSWAGEN 028903119P

I'm 99.9% sure that this web page has some of the makes/models that this pulley fits, so I can start there but its a bit of a rabbit hole.
https://infopart.org/ford-1469755-part

In an hour or so I'll start to pull the alternator when it's cooled off.

Appreciate any help thrown our way. Pura Vida! Help us get home!
Johnny
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1982 Diesel 1.9TD AAZ

[rlevans]

Could you weld the pulley (inside hub to the outer race(not to the shaft), and provided you can find a welding shop) solid until you find a new clutch pulley?

[johnnygreenham]

I must be getting tired on this trip because that is something I just did not think of and it is a great idea. I have no idea what metals the pulley is made from. Might be a tricky weld but totally doable. Lets make this our back up plan now and I like it.
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1982 Diesel 1.9TD AAZ

[Low Bräu]

That's exactly what I was thinking. If they are incompatible for welding you might be able to have a machine shop affix the two together by pinning or broaching it for a keyway. Another thought is they might be able to modify a new Japanese pulley or your alternator's shaft depending on what you have. Where there's a will there's a way. Good luck.
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Independent German Auto
671 Fern Drive
Merritt Island, FL 32952
(321) 449-4665

Specializing in repair and maintenance for Porsche, BMW, Mini, Audi, and Volkswagen.

1952 Standard Beetle
1960 SO-23 Westfalia
1961 L-380 Turkis Deluxe Beetle
1985 Vanagon Country Homes Camper (work in progress - EG33 swap)

[djkeev]

A freewheeling pulley, an over run unit?

Talk about complication of a simple device. Let's add bearings and lock up function to a pulley!

Can you get a solid pulley? It won't run as smoothly but will get you to where you can get the proper pulley.

This is a case of too much technology failing.

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[Low Bräu]

Here is a good read on decoupler style pulleys. They are being used on a lot of cars nowadays.

http://www.gates.com/products/automotive/passenger...ulleys-adp
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Independent German Auto
671 Fern Drive
Merritt Island, FL 32952
(321) 449-4665

Specializing in repair and maintenance for Porsche, BMW, Mini, Audi, and Volkswagen.

1952 Standard Beetle
1960 SO-23 Westfalia
1961 L-380 Turkis Deluxe Beetle
1985 Vanagon Country Homes Camper (work in progress - EG33 swap)

[johnnygreenham]

[?Waldo?]

While it may seem like excessive engineering, the high inertia alt used with the no-slip multi-v belt puts excessive loads on the end of the crankshaft. Without the decoupler alternator pulley, the crank sprocket will eventually fail and destroy the engine. I'd rather have the alt pulley fail than have the pistons mashing the valves. The D-shaped crank is better, but without the clutched pulley it too will fail in time.

[djkeev]

If your freewheeling pulley is whole, just not functioning as designed, simply remove it and have a shop weld the outer pulley to the inner shaft sleeve and run it as a solid unit for the duration.

If you lack the special tool to remove it, some very cautious welding utilizing steps to abate the heat build up would work, it would take time and pack with cooling ice to save your generator from damage, but it would work.

Even drilling some holes into the bearing gap and tapping it for some machine screw threads then run in some bolts locking the portions together could work.

Evenly spaced and sized to maintain balance.

Looking at photos of the Bosch pulley, would welding a large washer to the outer pulley and the inner bushing do the trick?


BTW, I understand the technology behind the pulley, but for rural trips as this, in my book simple is better where possible. There is more of a chance at performing simple repairs on the fly.

My Dad often spoke of the simplicity of the common Jeep during WWII and how they kept them going in the most dire of situations.

Having owned an early Jeep in the 1960's clearly illustrated his point to me.
This may have been the basis for my love affair with the early air cooled Beetles.

Dave
_________________
Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[MarkWard]

I am not able to look up the AAZ, but the AHU has this pulley number from Gates in the aftermarket. http://www.rockauto.com/catalog/moreinfo.php?pk=679060 Would that work? I see pulleys at IMC and World Pac for the ALH. I carry the tool, but will add a pulley to my list of spares.

Could that work? I can't imagine what the freight would be to get you the tool and a replacement pulley, but it is doable. mark
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☮️

[Butcher]

Not that this will help you at all, what was the brand alternator did you use? Pulleys do fail, but I have only run into them seizing which causes a lot of vibrations with the drive belt.

I have found if the sales pitch says it has a lifetime warranty, it's time to steer clear.

[SonnyApril]

If you can't find the parts needed in that town maybe find a shorter belt that bypasses the Alt. and drive in the daytime to the next town. A backup battery and solar charger might be a good investment if you go that route. Best of luck

[IdahoDoug]

Be cautious on the welding. A lot of folks down there weld, but this has to be welded perfectly square, and perfectly concentric. Otherwise, you'll have a crazy vibration even if its a little off. Even during the welding, the heating and cooling of the separate parts could cause asymmetry of the final assembly. So, doable but find the best guy in the area who can make or use a jig to preserve alignment while welding.
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[johnnygreenham]

From what I can remember, I tried to find one that was not made in Asia so i think the company was in California.......something like, LActrical, and from what I understand it was made in USA but I'm starting to think maybe it was just tested in USA
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1982 Diesel 1.9TD AAZ

[johnnygreenham]

Ok, so we struck out on finding any part that may work. We have ended up having to get it welded. The guy did a decent job. I think I will have to get a drill in the next few days and drill out some of the weld to even out the weight and balance it a little better. There is slightly more weld on one side than the other, not a huge amount but enough that I will probably do something about it in the next week. There are no vibrations coming from the alternator and you would not be able to tell the difference by sound but I can only test it at idle revving it with no load. Under load at 3 times the speed may be a different story and it may start to wear the alternator bearings quicker. This is just a temp fix until we get to Mexico where VW parts seem to be easier to source.
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1982 Diesel 1.9TD AAZ

[fleet_maintenance]

I enjoy good roadside fixes.
Would it be easier to weld another glob opposite rather than grind, provided there are no clearance issues?

[Jeff's Old Volks Home]

I too was left stranded by an overrunning overrun pulley. I ended up drilling and 'driving' 3- 6mm bolts in the clutch of the pulley to lock it all together, it would still be on the van if I didn't keep a spare one at the shop.
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www.jeffsoldvolkshome.com
2004 Jetta TDi Wagon
2002 Smyth Ute TDi
1990 Vanagon weekender Syncro AAZ
1987 Syncro Doka AAZ...soon to be TDI
2014 DL650ABS Xpedition
1986 Weekender Syncro (Under construction)
1987 Westfalia (Under construction)
1987 Syncro Single cab

[Witless Joe]

[?Waldo?]

I personally assisted a friend with an AHU that had the D-shaped crank fail. Yes, it had the decoupler pulley on the alt, but the pulley had seized and no longer uncoupled on overrun. I do not know how many miles he drove without the decoupler working. That wasn't specifically an AAZ with D-crank but the situation was the same. Mark that down as one firsthand account of failure. I have heard of several other similar AHU failures, but as they did not happen to me, they are now secondhand accounts. I'm sure if you go on TDI club you'll be able to track down several firsthand failed AHU D-cranks and of the folks in that group who then checked the alt for decoupling, virtually 100% will have had a locked up decoupler. If you feel there is no cause for concern, I would encourage you to run a solid alt pulley. Please report back how many miles it takes for your crank to fail.

[Zeitgeist 13]

MB also started installing overrunning alt pulleys as of '98 or '99 on their turbodiesel models. The '99 engine I put in my 124 wagon has one, and it looks and acts exactly like the version on my '02 ALH. These were added to higher torque engines for some reason despite the concerted efforts of bean-counters who were trying so desperately to keep costs down at the time
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?