by samsvan Mon Jul 02, 2018 5:07 pmI noticed that a bolt was missing from my alternator bracket and it had a crack in it. I went ahead and pulled the whole thing out to switch it out. Now I see that there are two bolts broken off in the block. They are both 5/16 grade 8 bolts. Of course they are hard to get at so I was thinking about trying to weld an old screwdriver to the bolts to pull them out. I tried drilling them to use an extractor but no luck. I can't drill straight in because the balancer is in the way. Am I screwed or what?
+6
jdlaugh
vanny
Digz
gfleduc
Scott
samsvan
10 posters
Broken bolts
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
Scott- Number of posts : 1651
Location : Anoka, MN
Age : 54
Registration date : 2008-05-20
If there is any bolt sticking out with threads you can put two nuts on it and back them into each other. You would have to be pretty good to get a screwdriver welded on there, and that weld would have to be pretty good to take the pressure it needs to loosen the bolts. Well, unless they are not very tight.
You might just have to bite the bullet and pull the balancer. Pain, but if it gives you the needed room to drill straight.
You might just have to bite the bullet and pull the balancer. Pain, but if it gives you the needed room to drill straight.
gfleduc- Number of posts : 376
Location : Kingwood Texas
Age : 69
Registration date : 2015-09-19
Well if you are good with a welder - I suspect TIG - It is a common practice in industry to remove broken bolts by the method - commonly they weld a bolt on so you have something you can torque with.
As a prep it is good to soak it a while with a pure penetrant - then of course clean it.
Let it cool because the bolt will be the hottest & you would otherwise also be fighting thermo expansion.
As a prep it is good to soak it a while with a pure penetrant - then of course clean it.
Let it cool because the bolt will be the hottest & you would otherwise also be fighting thermo expansion.
Digz- Number of posts : 3794
Location : United States Six Lakes MI
Registration date : 2008-05-17
Similar , make a half nut and try welding that on with a MIG. Or take a strip of thicker sheetmetal , drill a hole the same size or slightly smaller and weld that on and tap it with a hammer to get it loose. I have done that a lot with flush broken bolts from exhaust manifolds to bumper bolts.
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
Well I think I got lucky on this one. I decided to take my Dremmel tool with a cutoff wheel and make a slot across the end of the bolts so I could try to turn them out with a screwdriver. I figured they would be bottomed out in the holes and seized up but they came right out.
Scott- Number of posts : 1651
Location : Anoka, MN
Age : 54
Registration date : 2008-05-20
oh sweet, great idea
gfleduc- Number of posts : 376
Location : Kingwood Texas
Age : 69
Registration date : 2015-09-19
Nice! - good for you...
Digz- Number of posts : 3794
Location : United States Six Lakes MI
Registration date : 2008-05-17
^5s
vanny- Moderator
- Number of posts : 14778
Location : Ashburnham, MA
Age : 65
Registration date : 2012-09-22
Eggs Sellent!!! 
_________________
“The future will soon be a thing of the past."
http://public.fotki.com/Vintage-Vans/vintage-vans-es/ruff-diamond-1/?cmd=fs_slideshow
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
I'v been hearing my serpentine belt squeaking a little lately and then today, I noticed a lot of vibration when I was idling in gear, like at a stoplight. Turns out it was the same two bolts were broken off again. What would be causing this much stress? My motor is a '92 350 TBI and the only thing not stock is that we re-located the alternator down where the power steering pump used to be so it would clear the doghouse. There is no visible movement when I first bolt it together so whatever is happening takes a while to break the bolts. Any ideas?
jdlaugh- Number of posts : 298
Location : Tulsa, OK
Registration date : 2013-03-18
Could be the pulley is not exactly in-line with the serpentine system. That would cause a squeaking belt and put stress on the bolts.
donivan65- Governor
- Number of posts : 12245
Location : San Diego, California
Registration date : 2008-05-12
Are the bolts too long and bottom out so that they are not holding the alternator on REALLY tight? you using grade 8 bolts?
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
JD, I can't say for sure that everything is factory perfect but when I put a straight edge across the pulleys, they look in line. And Don, luckily the bolts aren't bottomed out. That at least makes them easier to get out. I am using grade 8 bolts and that made me wonder if using regular ones would allow them to stretch a little.
jrinaman- Number of posts : 890
Location : zelienople,pa.
Age : 60
Registration date : 2011-03-10
do you have a rear brace? while this may not fit your needs, you could likely find one that does or make one. https://www.lsxinnovations.com/product/ls-truck-low-mount-alternator-bracket-w-pulley-rear-brace/
jrinaman- Number of posts : 890
Location : zelienople,pa.
Age : 60
Registration date : 2011-03-10
panelmanrd- Number of posts : 801
Location : kcmo
Age : 63
Registration date : 2009-10-04
i had to make a braket that bolts to the rear of the alt that went over
to the motor mount bolt this stops the vibration of the alt and the broken
bolt thing went away
to the motor mount bolt this stops the vibration of the alt and the broken
bolt thing went away
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
I actually looked at those ICT brackets but there was some reason I didn't think it would fit. I guess making one is what I'm going to have to do. It looks like so much fun under there, I can hardly wait!
BILL Carson- Number of posts : 171
Location : harrison mi
Age : 68
Registration date : 2011-05-02
Thay do have an angle drills to do that
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
I got the bracket made and installed after work today. I hope I never have to change out my alternator again...
Vanny, can you rotate the picture please?
Vanny, can you rotate the picture please?
vanny- Moderator
- Number of posts : 14778
Location : Ashburnham, MA
Age : 65
Registration date : 2012-09-22
Not sure if this is the way you wanted it...just let me know...
_________________
“The future will soon be a thing of the past."
http://public.fotki.com/Vintage-Vans/vintage-vans-es/ruff-diamond-1/?cmd=fs_slideshow
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
Spin it a 180. The alternator should be to the left. Thanks brother!
Like this?
Like this?
panelmanrd- Number of posts : 801
Location : kcmo
Age : 63
Registration date : 2009-10-04
mine was very similar but i used one of the bolts at the block
where the motor mount bolt to, sometimes that bolt shown
in the pic is challenging to install due to alignment issues
where the motor mount bolt to, sometimes that bolt shown
in the pic is challenging to install due to alignment issues
panelmanrd- Number of posts : 801
Location : kcmo
Age : 63
Registration date : 2009-10-04
should stop the broken bolt issue
samsvan- Number of posts : 672
Location : Sarasota, Fl.
Age : 61
Registration date : 2014-09-04
sometimes that bolt shown
in the pic is challenging to install due to alignment issues
Ha! Tell me about it. My wife had to make the kids stay inside for this one.
Thanks for spinning the picture Vanny. You're a gentleman.
in the pic is challenging to install due to alignment issues
Ha! Tell me about it. My wife had to make the kids stay inside for this one.
Thanks for spinning the picture Vanny. You're a gentleman.
panelmanrd- Number of posts : 801
Location : kcmo
Age : 63
Registration date : 2009-10-04
when i was about 8 years old, my mom suggested
to my dad that he take me with him golfing one sat
that was the day i learned how to swear. profusely
to my dad that he take me with him golfing one sat
that was the day i learned how to swear. profusely
