After more trouble shooting I felt that the alt needed replacing and not just the rebuild kit. After removing the unit (what a PITA)... Ended up buying a RMMAL00134 Reman by Magneti Marelli for around $140 after tax and shipping. Went in without any problems and completely fixed my issue.
Best Alternator for Volkswagen Passat
I just replaced the one from my 1996 Passat Tdi. 326k miles on it. The alternator still works too!
I have a 1.8t motor in my Passat; but, I had to replace my alternator last January....and I took some pics...I went from a 90 Amp Valeo to a 120 Amp Valeo....the pulley had to be switched over to the new rebuilt unit (I went to an Alternator/Starter shop) ....old one on the left (90 A Valeo)....new one on the right (120 A Valeo)....
Bought the new Valeo, removed the Bosch, and got the Valeo installed. All is well, and I have a rebuildable Bosch 120A on hand-- no core charge w the new Alt.
B5/5.5 alternators come from two vendors, Bosch and Valeo. I've heard they're not interchangeable because of different pulleys.
Spent 300 on an alternator to get the whole car apart just to find out it was the wrong one
Upon only 3 days of ownership, the alternator went out due to the battery going bad, that took out the internal voltage regulator.
In the process of replacing the alternator..it was bad.
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