In the process of removing the drive belts so I could fix my 240's timing, I sheared the head off the adjustment bolt on the tensioner. Worse, the nut holding the tensioner in place is seized up tight, preventing me from removing it, and my efforts have resulted in rounded of the head (leading to enough colorful cursing that the strip bar up the street called and complained that it hurt their family atmosphere). Can anyone suggest some creative ideas to get the nut off and the threaded screw out of the tensioner? I've got a replacement (which I hope is long eonugh), but removing the old one if the trick.
Attached is a photo of my misfortune, labeled so you guys can see the problem. Does anyone have any ideas on how I can get these guys off? I've tried about three different brands of penetrating oil, tapping them, wiggling with a pair of vise grips, shouting at them... no luck.
Many thanks!
- Jack
Repairing drive belt tensioner on alternator
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jimmy57
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Remove the alternator and get where you can attack with full force.
The lower end of the slotted tensioner bracket has one bolt down in the round bushing.
The other is a longer bolt below alternator. A punch from the back side of the rounded bolt plus turning the bolt while at the same time rotating the tensioner piece where the remains of the broken bolt are located should brake it loose.
I don't know where you'll find a 6mm-1.0 bolt that long for the tensioning piece. The 8mm-1.25 bolt into the alternator will be an Autozone/Advance/Scheck's or whatever chain parts store item.
For several years they just used a bolt with flat washer and you pried the alternator over and tighten bolt while you held tension and it worked just fine.
The lower end of the slotted tensioner bracket has one bolt down in the round bushing.
The other is a longer bolt below alternator. A punch from the back side of the rounded bolt plus turning the bolt while at the same time rotating the tensioner piece where the remains of the broken bolt are located should brake it loose.
I don't know where you'll find a 6mm-1.0 bolt that long for the tensioning piece. The 8mm-1.25 bolt into the alternator will be an Autozone/Advance/Scheck's or whatever chain parts store item.
For several years they just used a bolt with flat washer and you pried the alternator over and tighten bolt while you held tension and it worked just fine.
I ended up using a bolt removal kit that Irwin makes. It has threads inside which cut into the head or nut when you turn it counterclockwise. Even with it, it was damn hard to get loose. 
I picked up a replacement tensioner from the junkyard. I'll probably still replace the long screw with one I got from the hardware store, though. First, it's not bent like the salvaged one. Second, it's a harder class than the one that was in there (10.9 vs what I believe to be 8.8, if I read the stamp on the top correctly). Hopefully I won't run into this problem again. I unfortunately realized when i pulled it that the bushings are terribly worn. *sigh* Always one more thing. I'll probably replace *all* the "accessory" bushings while I'm at it. Good thing this isn't my main vehicle!
- Jack
I picked up a replacement tensioner from the junkyard. I'll probably still replace the long screw with one I got from the hardware store, though. First, it's not bent like the salvaged one. Second, it's a harder class than the one that was in there (10.9 vs what I believe to be 8.8, if I read the stamp on the top correctly). Hopefully I won't run into this problem again. I unfortunately realized when i pulled it that the bushings are terribly worn. *sigh* Always one more thing. I'll probably replace *all* the "accessory" bushings while I'm at it. Good thing this isn't my main vehicle!- Jack
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