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I just replaced the one from my 1996 Passat Tdi. 326k miles on it. The alternator still works too!
You need to try using a OEM REMAN or OEM NEW alternator. Aftermarket items can really affect BSD.
After installing it, all of the intermittent electrical issues disappeared. I'm guessing the old alternator couldn't power all of the electrical issues at once, particularly since the battery light would not come on with the higher rev's of a cold start, but would come on with the low rev's of a warm start.
Sorry for the late reply. just to go ahead and close this out, it was a bad alternator. Took the 400 dollar hit to my wallet and bought a new one. Spent a few hours yesterday replacing it. So far I've driven it about 30 miles without the battery light coming back on. Thanks everyone for the help.
I'm using a MK2 Golf alternator. It has the correct mount width, and has the right frame to mate up with the nice rack and pinion style adjustment bracket also from the MK2 Golf.
When I had mine I had to replace the alternator just outside of warranty.
I've had 3 issues with the car: 3. recently - replace alternator (the car just knows I'm about to retire it).
My 540i at 141k started eating me alive, Alternator blew up
Upon only 3 days of ownership, the alternator went out due to the battery going bad, that took out the internal voltage regulator.
the car is a 1996 golf gl, 5 speed, with A/C (this is relevant to the alternator spec) Original problem, car not charging and replacement alternators were no good
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