You should be aware of an ongoing problem with rebuilt Bosch bus alternators having a too-long stud that causes an internal short. Chief symptom is usually a melted alternator wire.78wkndr wrote: ↑Sun Sep 03, 2017 7:35 pm
I just had my alternator rebuilt by a local shop.
I originally thought the wire shorted because of a pinch/rub situation but the rebuilder said a nut had fallen off internally and shorted the positive to the alternator housing. This resulted in the hot wire to the starter melting very, very thoroughly.
Old school alternator rebuild guy was appalled at the shitty quality of the rebuilt alternator I presented him so he rebuilt it properly with parts from it, a second alternator I had, and new parts as needed.
Somewhat unrelated but...but it cost about $140 to rebuild it but I happily paid a bit more to have somebody who seemed to give a damn do the work.
Ultimately I purchased a new alternator wiring harness through bus depot. Took a while because they were out of stock.
It has been discussed on numerous threads in the Bay Window forum over on TheSamba. A search in that forum should turn up some hits pretty quickly.
There is also a fellow over on TheSamba with the nickname "thatvwbusguy" who sells custom-built harnesses for our vehicles. I have one that he made for m Vanagon, and it's of first-rate quality. He's also quite a nice guy to communicate with and is extremely knowledgeable on the minutia of VW electrics.