Larry, I had some similar problems with my 1.9L before I got a new long
block from Boston Bob.  When I installed this in my '84, I was careful only
to put enough tension on the belt (new at the time) to get the job done.

John
----- Original Message -----
From: "Larry Chase" <roadguy@ROADHAUS.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, January 29, 2006 11:45 AM
Subject: 6 broken alternator in 3 yrs - possible root cause

Volks,

Alernator Brackets and Alernators.

Yesterday when I installed a new alternator ... I found that I also had
another "broken alternator
bracket".

Part #: 025.903.141C

Fortunatley I had a spare.

This was the 6th broken bracket in 3 years.

Several VW shops and I have tried to figure out the root cause of this
problem withiout success.

Observation:

Comparing the new Bosh Rebuilt Alternator with the old one, I noticed that
the base of the new alternator that
 fits into the alternator bracket (where the long bolt goes thru) was
significantly wider than the old unit. So much so that I had to file a tiny
bit of material off to get it to fit. The difference btween the new and old
alternators was 1/8" - 1/16".

Hypothesis:

Since the base on the old unit was narrower ... There might have been a
little slop when the alternator bracket was tightened down. Perhaps enough
to allow some misalignment and/or vibration.

I'm wondering if perhaps this is what may have caused 6 brackets to break in
3 years.

What are your thoughts?

larry chase
www.roadhaus.com