Infinitrium what did you end up doing with it?
I have the same problem with my 94 Golf TD
Check out mine:
http://www.youtube.com/watch?v=MuVO2PfzYvw
Srry for bad camera skills...
So from what ive read up so far, this is what i have to do:
a. find a good repair shop that actually knows what theyre doing
b. purchase harmonic balancer,replace belts and pulleys if needed?
c. Aslo, im still a little confused on this "JB" weld or the tdi fix, does it guarantee a permanent fix?
Ive checked the timing belt for a jump, all timings are good, pulled the valve cover and everything looks fine...
buy a tdi sprocket and take it to Canadian crank shaft and chrome, thats where I got mine done and it has been perfect for the past 2 years.
While you're at it, replace the alternator pulley with one from a TDI. They have a ratcheting mechanism which prevents the alternator's momentum from backdriving the serp belt. That, and a new tensioner cartridge should stop the tensioner from bouncing and wearing out the aluminum tensioner bracket.
where to buy just the clutched pulley?
got a part# on it?
I'm getting one from a local guy and this is the part number he mentioned in his e-mail quote: 028 903 119AA. $80 for the pulley.
Any special tools or headaches involved in replacing the alternator pulley?
Yep. You need a special tool, or as some on here will tell you, a pair of vice grips, a screwdriver and a few beer. :lol:
The tool kit to replace the pulley was quoted as $43, part number MN3400SET. I'm not getting the tool kit. A friend of mine rebuilds alternators so I'll pull the alternator and get him to do the swap for me.
Hope this helps.