Date:         Tue, 29 Jul 2008 22:42:02 -0400
Reply-To:     Chris S <szpejankowski@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Chris S <szpejankowski@GMAIL.COM>
Subject:      Alternator Bracket Mod 1.9 L WBX
Content-Type: text/plain; charset=ISO-8859-1

We were talking about broken alternator brackets yesterday, so I thought I'd
share with you what is probably done by many other 1.9L WBX owners.

The outer stud on the alternator bracket broke off and the nut on the inner
one was gone.  I did not know this until 4 years after I bought the van.  By
then the holes in the bracket have ovaled.  Amazingly, everything else was
intact.

I thought I'd stregthen the assembly by installing an additional tension
bracket like so:

http://i16.photobucket.com/albums/b7/misterpolak/Misc%20VW%20nuttiness/AlternatorBracketMod.jpg

I had an extra tension bracket, flipped it, bent it slightly to fit better,
installed the longer shiny carriage bolt in the alternator bracket,
installed a longer 8mm stud at the center of the engine to have room for the
extra tensioning bracket, and she's as solid as a rock.

I was not aware until later that 2.1L WBX has a similar second bracket from
factory.  I guess the engineers knew it was a weak area.


A potential fix for broken alternator bracket studs are "step-up" studs
where one side is 8mm and other side is 10mm.  You drill out the broke stud,
tap the hole out to 10mm with a special tap that allows you to cut threads
to the bottom of the hole, and install the 10mm side in the hole.  The
protruding stud will be 8mm just like the old factory part.  Ace Hardware
has these in stock in varying lengths, metric sizes and proper thread pitch.

--
Chris S.
"Beware the Subie Vultures"