It is common for the bearing opposite the pulley along with the housing or housing insert to fail. Once the bearing fails the rotor can also het the stator and even after the rubbing makes clearance the alternator will whine and have poor output. Time for a rebuild or new one. New reproductions are readily available now and usually even come with a pulley. The vibration can also cause the alternator bracket and/or mounting studs to break sometimes even damaging the engine case to a point of needing weld repair. The ultimate fail is the electrical fire after enough of the stator is destroyed.

https://www.amazon.com/gp/product/B00KY0CWPC/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1

Dennis
 

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of David Boan
Sent: Tuesday, October 30, 2018 3:40 PM
To: vanagon@GERRY.VANAGON.COM
Subject: alternator

I have a question about alternator repair.  A noise, like a vibration, started suddenly while driving.  On inspection I found that about 1/3 of the alternator fan had broken off and embedded itself in the engine cover (also making about a 1/2" hole in the cover).  My question is what might be the underlying cause, perhaps the end bearing?  Or just a metal failure?  The alternator, which is Bosch and about 8 years old, seems to be charging fine but the vibration noise is still there.  Just replace the whole thing?

Dave B.

Boise, ID