Late 70s alternator air boot question

[SGKent]

I put a lot of time into researching these some years ago. There is NO control by the people making these parts so unless you find a NOS VW one, you may or may not have what you think you have. Literally I had to order and return about 15 of the 55 amp boots to find ones correctly labeled, and the ones that were correct were old stock from VW. My suggestion is find a 70 amp boot and modify the shroud to fit if need be, or make an adapter.

[germansupplyscott]

[Globusoverland]

It has been a while since this topic was alive, but I will try to dust it off a bit
Here is my question:

I tried to find the answer and read the whole thread, but couldnt find it.

I have a small round inlet in the fan shroud, and want to connect the boot to a 70A alternator.
Has there been any part/part number for that??
(I have a 70 A alternator and want to install it in a early 74 bay/AP engine 1800, which has the shroud with smaller whole...)

Looks like I need to combine 2 parts to make it fit...

Thanks for your advice!
Michel

[Wildthings]

[ivwshane]

It was a little loose in my opinion. I didn’t have issues with the orientation of it.
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[SGKent]

[ivwshane]

I got mine from buslab.com, it’s not made by vw but it did fit.
_________________
77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[SGKent]

[Wildthings]

[SGKent]

just looking for an update. Just used the 021-903-655D one I had on the engine build I am working on, and it fit the shroud and alternator perfectly. It came from VW as documented earlier in this thread. The engine is a 1977 GD w/ 55 amp alternator. Has anyone found a source that has the correct part. I'd like a spare.

SK
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[SGKent]

All I know is that this one came from VW thru Paruzzi a couple years ago. I tried it this morning on my late GD shroud and it fits perfect on the shroud. Can't test the alternator side yet. The alternator is on its way to my friend Telford in San Diego so it can be tested for waveform since I replaced the brushes and bearings. It was a genuine Bosch rebuild that came from Bus Depot in 2009 and started squeaking on the last trip to Yosemite with only about 2500 - 3000 miles on it. Not Ron's fault. The bearings in this were an off brand Chinese set, so I replaced them with non-chinese SKF and FAG bearings plus added new brushes from NAPA. I tried test fitting the boot to the GD shroud and it is tight, fits just right.

I do not believe VW has anymore of these. Also, in 2009 I used the model boot that was too small for the GD opening but barely stayed in it. When I removed the shroud last week, with age, heat, and the internal expansion ring, it had expanded to be tight in the shroud. I hope this helps. FWIW I offered to numerous people to use this one from VW to make a mold but now time is up and I am going to use it. I do hope the community eventually gets this sorted out. I think when this all began I had to return about 10 - 15 mislabeled ones to different vendors. If you have a late shroud, you want the D version. See part number on the part itself in the photos below.

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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[Salders]

Auto Atlanta remakes them so the part number isn't molded on the boot but from the picture, it looks like the right one.

http://www.autoatlanta.com/results.php?partnumber2=021%20903%20655%20D

021 903 655 D

If anyone orders it please let me know if it's actually a D part

[Wildthings]

[Jetfxr69]

[ivwshane]

So I just got the boot from 914rubber and it is incorrect. There are no part numbers on it but it matches the description of a “B” part.

Interestingly, my existing part is labeled 021903655B and looks completely different.

Note that my existing “B” has a lip on the fan shroud side for a spring clip* (I don’t know if that is the correct name for it) and the new part does not.

_________________
77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[Busdepot]

Thanks, if I get one that is purported to be correct and doesn't look like the other two, I'll take you up on that offer.
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- Ron Salmon
The Bus Depot
www.busdepot.com

[sjbartnik]

Ron - I still have the D boot (genuine VW part) I bought from Bus Depot 20 years ago in my possession. I could take measurements if you tell me what you wanna know. Presumably the diameter of the fan housing side based on what I'm reading in this thread.
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1965 Volkswagen 1500 Variant S
2000 Kawasaki W650

[ivwshane]

[Busdepot]

Thanks for the clarification.

Looks like this is an issue of a bad part number cross-reference from our supplier. It seems the one we list as a 655D is in fact the 70 amp one like our site says. So our website description is correct, but our part number reference is wrong, it should be an 022903655. I will see if we can get an actual 655D and if so bring in a sample to compare to the other two versions we have.
_________________
- Ron Salmon
The Bus Depot
www.busdepot.com

[SGKent]

Ron at BusDepot. This part gives people fits because many repros are mislabeled. I bought (and returned) six to ten of them until I found an original from VW that fit. We aren't talking small differences.

The general consensus is:

021-903-655 B small hole in fan housing, early T4 55A. Falls out of late engine shroud.
021-903-655 D big hole in fan housing such as late T4, GD, GE engines
022-903-655 70 Amp alternator

I'll take photos soon of a GD shroud when my shroud is off. Ivwshane is correct.
_________________
"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin