Impossible Alternator Bolt
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Joined: Sep 2004
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Impossible Alternator Bolt
I am trying to take the alternator out of my 1995 ford f150 4.9 liter. The top bolt was no problem the bottom bolt is a different story. The long bolt that passses through the alternator into a threaded bracket behind the alternator will not break lose. It is as if the metal bolt and the aluminum bracket have welded themselves together. I have tried wd-40, fluid film, heat on the bracket, a breaker bar and the bolt will not budge. I am thinking my next step is to remove the grill and the rad and atack the bolt with an air impact wrench from the front? Any ideas? Thanks
Post Fiend
Joined: Oct 2003
Posts: 6,214
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From: New Jersey
Since the bolt is long, I'd cut the head off at the front with an angle grinder, slide the alternator forward, and remove it that way. Then you have the long bolt shaft exposed for some purchase.
Heat the threads (of the bracket) with a propane torch, and apply candle wax so it whicks in. You might have to do that a few times... Then torque it off with vice grips and replace the bolt.
Heat the threads (of the bracket) with a propane torch, and apply candle wax so it whicks in. You might have to do that a few times... Then torque it off with vice grips and replace the bolt.
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I think you may be right about the bracket. I am thinking my other option is a sawzall with a metal blade, To cut the bolt off at the front and back of the alternator. I don't care about wrecking the alternator I don't need the core. I was thinking about removing the whole aluminum bracket but one bolt is behind the alternator. I can get vise grips on the head of the bolt but not a hope in hell of breaking it lose. I guess thats what i get for washing my engine all the time.
Cargo Master
Joined: Jan 2004
Posts: 3,118
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From: South Dakota
I would get a long breaker bar, certainly SOMETHING will give. I have a 1/2 inch drive breaker bar about 25 inches long, that thing has saved the day for me many a time. If you try this method be sure to use a good six corner socket and when it starts to move work it slowly back and forth instead of trying to turn it straight out. Good luck with whatever you decide.
Post Fiend
Joined: Oct 2003
Posts: 6,214
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From: New Jersey
A breaker bar will work, but what happens if you snap the bolt right at the threads behind the alternator? Then you have to drill it out, and helicoil.
Would be much less aggrevation (I think anyway) to hack off the head of the bolt in the front, then have something to grab.
But you can still heat the threads at the back if you can get at it, then let it sip the wax from a candle. Certainly worth a try.
I just absolutely dispise drilling out bolts, studs, etc. I've done enough to immensely hate this process. That's why I tend to cut things to give me some purchase...
Would be much less aggrevation (I think anyway) to hack off the head of the bolt in the front, then have something to grab.
But you can still heat the threads at the back if you can get at it, then let it sip the wax from a candle. Certainly worth a try.
I just absolutely dispise drilling out bolts, studs, etc. I've done enough to immensely hate this process. That's why I tend to cut things to give me some purchase...
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