I discovered my fan had a wobble... water pump bearing. OK, time for a new pump. I did my homework here and learned that the passenger side lower bolt is "wet" and needs sealer. Got one from O'Reilly. Drained coolant and started in.

Since I installed a/c in my truck 20 years ago using a York compressor and factory brackets, I had to remove those brackets first - no problem so far. Then I started removing the alternator and promptly found that the long 7/16" bolt was rusted absolutely solid to the alternator (it would turn in the block when rotating the alt, so the threads at least weren't frozen). Nothing would budge it.

I ended up cutting the head off the bolt so I could remove the pump with the alternator bracket assembly attached. Then I had to cut the bolt (and spacer) again behind the alternator to remove it from the truck. With my 12-ton press maxed out, after a few seconds, the bolt moved about 1/2" with a loud bang. I couldn't get it to move again, so I drilled a 1/8" hole most of the way through it, then a 5/16" hole, then applied the press again. That got it moving, and a few hammer blows with a long punch finished the extraction!

Everything else went back on with no problems (extracting the heater hose nipple wasn't too bad)... now I just need to find a 5-1/2" long 7/16" bolt, and make a new spacer. This ~1 hr job turned into 4 and I'm not quite done yet.
Note to self: Remember to put anti-seize on the (new) bolt this time

 

I don't know why, but 7/16 bolts can be hard to find. Your best source might be one of the guys reading this.
Eric.

 

Hi DrCharles, Sounds like you did the work...taking on the "events" as challenges.That is the surest way for happy endings.
Yes...Never Seize or axel grease on the "wet" bolt will help you next time the water pump goes out.
Good on ya.

 

Thanks for the compliment... but the wet pump bolt came out just as easy as the other three It had some kind of sticky sealer on it, too.

The problem child was the long bolt that goes through the alternator! 20 years of dissimilar metal corrosion took its toll. It always amazes me how hard rust can stick when you don't want it to...

Fortunately, it appears that Tractor Supply Co. has 7/16" all-thread, (and 7/16" bolts also, but only up to 3" long). Last time I was looking for a large bolt (6 x 5/8"?) in fine-thread, they had that too Hirsch Farm & Feed, and Ace Hardware did not. So I'm glad they opened a TSC in my town just a month ago!

Edited to add: my local Fastenal has 7/16-14 x 5-1/2" bolts too, but in a package of five for $13...

 

BoltDepot.com has 7/16-14 x 51/2 in grade 5, grade 8, and stainless steel. You can buy one bolt but shipping is about $11.

 

Charles....don't use all-thread. It's low grade (2) and not very strong. I'm sure we can find whatever bolt you need. Also....may have a spacer, but I'll have to look.

 

Tractor Supply had 7/16"-14 Grade 5 bolts up to (at least) 6 inches. No half-inches above 4" though, so I bought a 6" for a buck and a half, and removed about 1/4". Perfect.

I also found a piece of 1" aluminum rod stock in my scrap pile and made a new alternator spacer - drilled a 1/4" hole down the center and followed with a 3/8" and finally a 7/16". Not sure what alloy but it sure was tough to drill!

Now the alternator is firmly back in place... with plenty of anti-seize on this new pivot bolt!