T5 2.5 TDI Alternator Issue

**summersky** · 11-01-2023, 02:31 PM

The seller I bought my T5 from told me the alternator regulator needed replacing.

My van has 360,000kms on it. Am I better off replacing the whole alternator while I’m at it?

Can anyone recommend where to buy this from ideally within Australia?

**BrianJ** · 12-01-2023, 07:04 AM

Are you taking their word for this? Have you checked the voltage of the battery when the engine is running, should be somewhere near 14Volts. Assuming the regulator is faulty, how could you be sure the slip ring brushes aren't worn down, so to be sure you either need to get the whole alternator reconditioned, if it is possible in Australia, or buy a full new one. I recall the man who does the repairs at the local VW shop that I go to, telling me that it is impossible to buy the parts for the alternator separately in Australia. This info could be wrong as i have never had to do this myself yet, but I am sure the day is coming when I will as mine has done 345,000km, so I will be watching this message thread.

**Rebuild** · 13-01-2023, 08:45 AM

checked the gates coupling to see if alternator has consistent drive?
the couplings are a maintenance item. 180K km replacement, i think

**summersky** · 13-01-2023, 03:50 PM

Originally Posted by Rebuild

checked the gates coupling to see if alternator has consistent drive?
the couplings are a maintenance item. 180K km replacement, i think

I’m slowly working my way to that. The gates coupling for the alternator is exactly the same as the one for the ac compressor right? I might as well check the ac compressor coupling as well.

I’ve clearly bitten off more than I can chew attempting this myself!

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**Rebuild** · 14-01-2023, 01:26 PM

yes, i think they are the same, but check part nos. if you're concerned.
I'm at 190Kish km .
Haven't replaced them yet. Alternator coupling has about 1mm slop

**summersky** · 14-01-2023, 01:57 PM

Originally Posted by Rebuild

yes, i think they are the same, but check part nos. if you're concerned.
I'm at 190Kish km .
Haven't replaced them yet. Alternator coupling has about 1mm slop

I’m going to put the front back together and take it to a mechanic. I should have done my homework before attempting to tackle this.

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**Rebuild** · 14-01-2023, 08:25 PM

T5 2.5 Alternator removal - The Brick-yard

**summersky** · 17-02-2023, 01:12 PM

To give you all an update on this. After putting the front all back together, I decided to take it apart again and take the alternator to a sparky to recondition and replace the coupling bearing/cog for me.

In doing this I discovered the bolt that holds the engine-side cog to be snapped thereby explaining why the alternator wasn’t working.

Has anyone had this problem before?

After reinstalling the reco’d alternator and putting everything back together, I tested the battery and charging system and all works

Feeling very chuffed that I managed to sort this out myself!

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**Silver Caravelle** · 17-02-2023, 04:41 PM

Top effort Summersky.

I haven't experienced a snapped bolt...thus far. Do these alternators free wheel on and off base on load or are constant drive? Cheers, Scott