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Broken bolt at engine for alternator tension. 200

Greetings All, hope your volvo is good.
I just realized the bolt holding the tension rod to the engine for the alternator in my 83 240 has broken off flush.
I'm planning on using the alternator bracket/brace and its bolts to somehow rig up another way to attach the tension rod.
Has anyone had any success using a like repair?

Thanks in advance.

Joseph in sunny New Mexico








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    Broken bolt at engine for alternator tension. 200

    If you still have the block that the tensioner bolt goes through and only the head side is broken off, you might be able to salvage it. Remove the adjuster block. Heat it red hot. Use vice grips to grab the block and the protruding end of the tensioner bolt and unscrew the broken bolt.

    This has worked for me more than once. If you can find a replacement bolt (M6 X 1.0 thread) that is 8.8 grade (comparable to SAE grade 5), it will be less likely to break. A little neverseize will help too.

    Greg








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      Broken bolt at engine for alternator tension. 200

      Hi Riverbend,
      The bolt is broken about 1/8" deep in the screws hole. I then tried using an reverse easy out, drilled a hole in the broken bolt, tapped in the easy out then attempted to reverse the bolt out. Then the easy out broke off in the hole. This only seems to make my problem worse.








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    Broken bolt at engine for alternator tension. 200

    Are you talking about the turnbuckle, the pivot bolt or the bolt that holds the adjustment (ran out of right terms the one that goes through the ear on the alternator into the sliding bracket)? Turnbuckle is a nice to have but once the alternator is adjusted and both pivot and the other bolt are tight, it can be backed off 1/2 turn...it does NOT hold the the adjustment or at least should not.

    So unless you are talking about the bolt that holds the sliding bracket to the block through the accessory bushing, all you have to do is figure out how to tension the alternator (I us a 2" x 4") and then tighten down the pivot and and bolt to the bracket.








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      Broken bolt at engine for alternator tension. 200

      I'm talking about the bolt that attaches the tension rod to the engine. But now my problem is worse. I drilled a hole in the broken bolt in order to use a reverse easy out. Then the reverse easy out broke flush at the engine. I cannot figure out how to get the broken easy out out now.








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        Broken bolt at engine for alternator tension. 200

        You need to drill out the easy out with a diamond tipped bit. That's the only way to get it out now.

        A dremel works best for this.

        Good luck!

        Matt







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