Alternator/Power Steering bracket
 

I have, for the 3rd time, had the cast aluminum bracket break to which my power steering pump and alternator mount on my '02 F250 7.3L. Last time the bracket alone cost me $221 as a carry-out item. (First two times were under original warranty)

What sources are there besides paying the dealer $221?
I asked LKQ and was told they don't separate the bracket from the motor, and I'm not going to pay $3800 for a used motor just to get the bracket.

Ideas, suggestions?

Do you know what is causing the break to happen?

No, I don't know what is causing it. First break came at about 73K miles, second bracket break came at 81K, and this one came at 164K. They have all broken in the same place, too. They break across the opening in the bracket through which the pulley shaft from the PS pump protrudes.

And, yes, I have changed the PS pump, at 81Kmiles ('cuz that's what the Ford dealer said was causing the aluminum to fatigue and crack), and again at 145K miles, when the pump began leaking past the seals.

Were is it breaking? That bracket is pretty beefy. Can you take a picture of the break?

Is there somthing between the bracket and block causing it to not sit flat and when you tighten the bolts it puts it under stress?

I'll get a picture of the break tomorrow, after church is over.

once, MAYBE, but to break three times there's got to be a reason causing this and i'd search for the cause.
i have no ideas but i have had that bracket off of mine and i know its solid.

Fuel rail Plug causing it not to sit flat? Does the bracket have a big enough recess on the underside to clear this plug? There is also a 4th mount hole. Just below the picture shows.

http://i233.photobucket.com/albums/e...ool/plug-1.jpg

I pulled the broken bracket off, and found the stub of a broken bolt or stud behind the bracket, protruding about 1/8" to 3/16" from the head. It appears to partially line up with a recess in the back of the bracket. The local LKQ auto parts guy says my truck probably was OE with the dual alternator setup, which uses a different bracket. Unfortunately, he didn't have a replacement in stock, nor one in Florida. So now I go cry to the dealer who replaced the bracket last time, and demand to know why their tech didn't remove the broken stud or bolt the last time they replaced this bracket, 2 1/2 years ago. Wish me luck.

Actually as far as I know, the bracket on the drivers side, which includes the powersteering pump, and alternator, is the same, whether or not it has dual alts or not. The optional bracket is on the passenger side. I have been askeed before at the ford garage which side the alternator was on, so they can put a secondary alternator on the drivers side somewere, but I think standard dual alts, is drivers side, ontop, and passenger side, on the bottom.