My latest problem / project. 1979 Bronco / 351M.
Ever since the engine rebuild, the alternator mounting bolt snaps off at the head, about every 2 years. The last time it broke was the worst. I drilled out the bolt and broke an easy-off into the hole. I then ruined several cobalt drill bits trying to remove the easy-out & remaining bolt.

I found a local shop & mechanic who knew how to 'blow-out' the bolt & easy out with a cutting torch & clean up the threads with a 7/16 tap - he charged me $20 and it took about 15 minutes.

The mechanic found that there was 3/8 heli inserted into the last ~ 1/2 inch of the hole - preventing the Ford 6 1/4 inch x 7/16 alternator bolt from being properly torqued. He was unable to remove the heli.

There was still a good 1/2 inch of useable thread remaining. The alternator bolt is no longer stocked by Ford - according to the local dealer. Went to the junk yard and found a bolt and the 2 1/4 inch steel spacer from a 351W - cost $2.00. But, I decided I did not want to fix this again in another 2 years and decided against the standard Ford design and installation.

So, I came up with another method for re-attaching the alternator. It works great - but I have only driven on it for ~ 10 hours. Will let you know if it fails again - but I expect the design & installation will outlast this engine. It sure makes installation of the alternator alot easier!!

Cost of new installation, approximately $20.00. 4 1/2 x 1 inch diameter grade 8 bolt - $8.00. Machining at local machine shop $10.00. 2 - 4 1/2 inch x 7/16 grade 8 bolts $2.00.


Machine the top of the 4 1/2 x 1 inch bolt hex-head flat (remove the grade 8 markings, the smooth surface mounts against the head). Cut off threads, the remaining bolt length (shank + head) should measure the same as the Ford spacer - mine was 2 1/4 inch length. Drill and tap completely through the center of of the 1 inch diameter bolt with 7/16-14 tap.

Next cut the threads off of one of the 4 1/2 x 7/16 inch bolts. Keep the threads - this is the 'stud' that will attach the 1 inch diameter center tapped bolt to the head.

Next, using red thread locker, insert the 'stud' into the hole on the head and attach the center tapped bolt to the other side of the stud (place the machined flat hex-head of the bolt against the head). Make sure that you have at least 1/2 to 3/4 inch stud into the block and the center tapped bolt. Carefully torque the center tapped bolt to the engine block - the hex-head was ~ 1 1/2 inch - use big wrench!!

At this point, I allowed the thread locker 24 hours to cure.

The next day, I attached the remaining 4 1/2 inch grade 8 bolt through a lock washer, the alternator mounting bracket, the alternator, and into the center tapped bolt.

Then I attached electrical wiring, the lower mounting bracket to the alternator, tightened the belt, then torqued the lower attach bolt and then the upper attach bolt.

Good luck to all!! Have pictures & diagrams if anyone is interested.

 

Please post pics and diagram in your gallory would love to see them.
Also I saw someware on here i think in General Conversation
a Requesting Articles post from modirators you might want to post what you rote and pics there to might get it on you never know then more than just us can see it.
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