Author Topic: TDI clutched alternator pulley on an AAZ alternator.... (Read 6681 times)

Vincent Waldon · « **on:** October 30, 2007, 11:56:40 am »

There's lots of info out there on this particular swap but it all ends the same way:

"You need about 80 bucks in special tools to get the old pulley off and the new pulley on".

Anyone done it ?? Had it done ?? Care to comment ??

Vince

insdtanoodles · « **Reply #1 on:** October 30, 2007, 02:49:00 pm »

I did mine no problem, took my old pulley off with my impact gun and put the new pulley on. Now if I ever have to get it off I can see there being a problem seeing that I dont own the special spline like tool.

Vincent Waldon · « **Reply #2 on:** October 30, 2007, 08:18:06 pm »

Quote from: "insdtanoodles"

I did mine no problem, took my old pulley off with my impact gun and put the new pulley on.

Thanks for the response !

I can see getting the old pulley off with the ole air-powered persuader, but am a bit mystified on attaching the new pulley without a spline tool:

It looks to me like there are two spines involved... a big outer one on the pulley, and an inner one on the long, tube-ish nut (not shown in the picture but implied by the "official" Metalnerd tool.

Did you just use the original nut from the old alternator ??

One other thing... search reveals two part numbers:

028 903 119AA and 038 903 119A. My supplier can get me the second one but not the first... any idea which part you used ??

Thanks again for your help!

Vince

Jetta Fan · « **Reply #3 on:** October 31, 2007, 05:22:35 am »

Hey Vince, I've been saying for a year now I've been going to do this and just never got around to it yet. I've talked with the guy that does my starter and alternator rebuilds for me and he says it's an easy swap (mind you, he has the tools). I checked with a local supplier and here's what he provided for a quote:

028 903 119AA for $80 (pulley)

MN3400SET for $43 (tool set to install/remove the clutched pulley)

He doesn't mention the second number you mentioned.

However, a quick check on ETKA turned up this info:

028 903 119AA is for the 120 Amp alternator and

038 903 119A is for the 70 and 90 Amp alternators.

Hope this helps.

I put the pulley on my Christmas wish list. :lol:

bert · « **Reply #4 on:** October 31, 2007, 01:59:18 pm »

I did it,the tools in the uk cost £20 good mod,stops belt bouncing about.

Bert