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I managed to break off the bolt that holds the tensioner,has anyone got any ideas what would be the best way to solve this problem? thanks for any help!
If you go to Sears, or your favorite on-line tool supply, you can get "bolt extraction" kits.
If you have enough of the bolt sticking out, you can try the ol vise-grips + torch on the metal around the bolt to expand it. Don't heat up the bolt, you dont' want it to expand.
Should'nt be. If there's thread showing, you'll be able to tell just looking at it. If you're using an easy out, and there's a tad bit of the bolt stickint out, use a Dremel tool or mini grinder to flaten the end of the bolt, then use a centre punch to dimple the centre of the bolt before drilling. It'll help keep the tip of the drill bit from wandering around and driving you nuts. And heat the casting up a bit to help, or use penetrating oil.
"Easy out" theres 2 lies in one phrase! Never is easy, and rarely comes out. I would try one anyway though... Otherwise just keep drilling the hole until its so big you can peel out the remainder of the old bolt and put a new one in. If your good you shouldnt even have to use a tap. Otherwise drill it and tap a new hole.
I broke one of these b4 changing the spring loaded belt tensioner on my 92 Crown Vic. Just maybe its close to being the same. The one I broke was in a hole that wasnt blind and was able to back it off from behind until there was enough to grab from the front. I used vise grips and backed the whole thing out. Otherwise trying to get a drill in there Id have to take half the front of the car apart. Look around with a mirror and see if you and see the end of the bolt.