T5 alternator design=fail..

[gtimk5]

Wow, just pulled my first T5 2.5tdi alternator off yesterday. What a dumb design, I am not sure what VW are thinking these days as the alternator, powersteering pump which also drives the A/C pump via a toothed joiner all run off the gearbox end of the motor using no belts off the crank, rather, must be some planetary gears in the end of the motor.
It entailed removing the front of the vehicle, the inlet manifold and hoses ect. Major job, only to find that the toothed sprocket on the alternator must have some kind of harmonic balancer setup internally which had failed. Special tools are required to remove this thing and the part? $520 retail thanks very much!
As much as I am over old aircoolers, VW make things so difficult these days...

Beware T5 owners, this vehicle has covered 103000 kms.
Andrew

[Golf Loon]

Have you see the internal powersteering pumps which fail and pump power steer fluid into the motor and motor oil into the steering !

[gtimk5]

Havent seen that Loon, another modern design feature eh...

[Golf Loon]

Yup, its good ay?

Just changed our first Golf 5 DSG today as well!

At 112,000ks.

[Transporter]

Scary posts, guys.
Knowing my luck, I should start saving.

[velly_16v_cab]

the world of car design has change, service has nothing to do with it.its just how can it be assembled on the assemblyline...

the joys of working within automotive....good job i work for Ford so i can mess up there designs lol

[Golf Houso]

Can't be as bad as the 88' excel:



The alternator bracket was integrated into the block, so you can imagine what will happen when you have to change that

[gregozedobe]

AFAIK VW won't be putting the R5 (2.5 5 cyl TDI) engine into Transporters any more (starting from the FL due out soon). So goodbye to the gates couplings (toothed rubber drive for alternator and A/C). I have a feeling I might be selling mine just before the extended warranty runs out

[Shifter]

Jeez,
That's a worry, I have only just bought one!!

[Transporter]

Wow, just pulled my first T5 2.5tdi alternator off yesterday. What a dumb design, I am not sure what VW are thinking these days as the alternator, powersteering pump which also drives the A/C pump via a toothed joiner all run off the gearbox end of the motor using no belts off the crank, rather, must be some planetary gears in the end of the motor.
It entailed removing the front of the vehicle, the inlet manifold and hoses ect. Major job, only to find that the toothed sprocket on the alternator must have some kind of harmonic balancer setup internally which had failed. Special tools are required to remove this thing and the part? $520 retail thanks very much!
As much as I am over old aircoolers, VW make things so difficult these days...

Beware T5 owners, this vehicle has covered 103000 kms.
Andrew

Mate, can you tell us please, if there were any additional driving lights fitted or second battery or two.
These couplings should last 120,000km when they should be replaced. I'm just trying to figure out how it happened and what caused that. Could it be the extra load on the alternator?

[gtimk5]

No extras at all bar a whip aerial on the front. It does a bit of longer distance driving. Well maintained 103000 kms on the clock.
If I remember to bring my camera to work I will take a couple of pics of the disassembly required.
Apparently there is a Toureg here that had one replaced and wasnt set up properly on assmbly and has since done 3 more pullies.

[Shifter]

Oh. not additonal load on the alternator due to driving lights and a second battery - Jeez, how long have I got, before the dreaded electrical death?

[Transporter]

Oh. not additonal load on the alternator due to driving lights and a second battery - Jeez, how long have I got, before the dreaded electrical death?

It doesn't have to be load related. Could be just a faulty componnent.

Coupling Gates p/n EG1
Fits the following:
Transporter 2.5TDI……96/120/128kW AXD/AXE/BLJ
Touareg 2.5TDI……….120/128kW BAC/BLK

[Umai Naa!!]

The drive couplings usually fail when the A/C compressor locks up and seizes.

The front of the car, nor the intake manifold need to come off to remove the alternator. You still need to put the front of the car into 'service mode', but the job is still relatively straight-forward.

[Guest0608]

replace the belt and the a/c/alternator freewheel and you should be ok, just check that the a/c compressor has not seized, usually just the free wheel that ripps off the teeth on the drive belt -VW-