Broken bolt
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8th Gear
Joined: Apr 2017
Posts: 8
Likes: 1
Broken bolt
I was driving home and my belt tentioner bolt broke and the tentioner fell off. I pulled the whole braket off to remover the rest of the bolt. I tried 2 easy outs but they both broke so I decided to come from the back and I've drilled it out to the point that it is paper thin but it still refuses to come out and I'm at an absolute loss. I've tried soaking it in penetranting fluid and heating all around it and still nothing. I'm just lost.
More Turbo
Joined: Oct 2019
Posts: 558
Likes: 109
I've sometime had to use a pick or something to go in and try bend it in ,if its no big deal you could drill it out and tap one size bigger then you might have to also drill the new tension bracket bigger
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Lead Driver
Joined: Jan 2019
Posts: 5,066
Likes: 863
From: N.W. Alabama
I'm with Prototype...I found this-->Per my official 1992 Ford Factory Service Manual:"5.0,5.8,7.5 (tensioner) idler pulley retention bolt have a left hand thread,requiring a clockwise motion to loosen." Also:"Excessive rearward force on the bolt during removal may over-stress and crack the tensioner arm."
When replacing the pulley bolt--torque to 55-65 foot pounds.Use 16mm wench.
Note--this left hand thread refers to the 16 mm bolt that the pulley rotates around--not the 19mm bolt that holds the tensioner assembly to the alternator bracket.The 19mm tensioner bolt was a right hand thread on my 92 F150 and it should be torqued to 51-87 foot pounds--per my FSM.
When replacing the pulley bolt--torque to 55-65 foot pounds.Use 16mm wench.
Note--this left hand thread refers to the 16 mm bolt that the pulley rotates around--not the 19mm bolt that holds the tensioner assembly to the alternator bracket.The 19mm tensioner bolt was a right hand thread on my 92 F150 and it should be torqued to 51-87 foot pounds--per my FSM.
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Tuned
Joined: Dec 2018
Posts: 454
Likes: 97
From: SE WI
If you have a broken off bolt like that, and it's lefthand thread (allegedly), what I have found works is to take a junk larger drillbit (or a junk reamer) and sand down the junk bit until it's tapered. Hammer that dirty girl in there and run it out.
Lead Driver
Joined: Jun 2021
Posts: 5,215
Likes: 803
I would just finish drilling the thing if its paper thin and then tap for another size up, The new tensioner, if it is like what im thinking , should have a sleeve that runs through the center and that would probably take the size of the next thread bolt , but without any pics all of us are pissing in the wind here.
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