Clutched Pulled on Alternator Seized
Answered my own question - Thanks to others’ posts on this BB!
Went to garage; opened the hood; locked tensioner open; shoved chop stick between alternator check hole and plastic fans inside alternator. No Clutched Pulley. (*Ta*Da*)
Ordered replacement part from Discount Import Parts (http://www.discountimportparts.com/
)- it was stocked within two hours; ordered special tool MN3400 from Metalnerd (http://www.metalnerd.com/
)- it was in mailbox two days later.
Replacement is as simple as a 14mm socket on a breaker bar and a 17mm open end wrench; Tri-flow to loosen pulley threads from alternator - turn open end wrench counter-clockwise to loosen; replace pulley; tighten; wipe area clean; set belt; and release tensioner to unlocked position.
Wolfe (2005 TDI 5sp wgn) purrs like the day it was new. It is amazing how a clutched pulley on an alternator can make such a drivability difference. There is no belt vibration at start or during fully wheel turn lock. I can also hear again the variable pitch turbo whistle on and off at low speeds like it did when new.
Awesome BB! Thanks.