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foxriverat

Alternator bolts broke in block

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foxriverat

Went to put new belt on my 2000 response with monsoon. When I loosened belt to winterize I knew something was funkey. 2 bolts on lower left of bracket are just bolted to alternator. They are supposed to go into block but are snapped off. Bolt on top right went through bracket behind alternator to keep it tight. Can I try drilling them out? Or do I risk drilling through block? Hope the picture shows up. https://www.dropbox.com/s/c6tf8omvd3one4x/20180430_135900.jpg?dl=0

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drh

Are they sticking out of the bock enough to get some vice grips on and try to unscrew them? Picture doesn't show. Wondering how they snapped off. You shouldn't ever have to loosen those right?

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electricjohn

Only bolts you should  have loosened are top and bottom of alt., not the bracket.  You were just given a lesson  in hydrogen embrittlement.  Try what drh recommends but use a good penetrating fluid and some concentrated heat on what's left of those bolts.  Stretch it out over days if necessary.  If you can't do what drh recommends, learn what a left hand drill bit is.  Good luck

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oldjeep
9 minutes ago, foxriverat said:

Bolts were already busted off in block. Someone rigged it to work. Just picked boat up last year. They don't stick out. Just wondering how deep I can drill to get easy out in there without going through block. Here's a pic https://www.dropbox.com/s/kx3zis5bcevtcc5/Screenshot_2018-05-07-14-09-39.png?dl=0

Use a left handed bit as suggested before resorting to the easy out.  You should hit air before you hit the block, but there is no point in drilling more tgan 1/2 inch deep. 

When you drill with a left hand bit, no lube and lean on it.  You want it to bind and spin the bolt stub out

Edited by oldjeep

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foxriverat

Thanks. I will try to find some left handed bits tommorrow. 

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MadMan

You have one thing going for you in this endeavor.  Since they broke off, they're probably not a hardened, grade 8 bolt.  More like Home Depot grade 0,  which are much easier to drill into.

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Slurpee

Oh boy.  I remember this from when I upgraded my alternator to a 200A job on the '01.  Laying down in the back in 105 degree heat.... meticulously slowly drilling a hole in the center of the bolt with a Dremel because the drill was too large to maneuver back there.....  Constantly dripping cutting fluid on the bit so it wouldn't destroy itself..... and then widening the hole one bit size at a time....  lastly holding my breath as I lightly hammered the ease out into the bolt and cranking it out... it worked!!!  the second time!  Try to do it right the first time by not getting impatient like I did.  If it takes an hour to do it right, then take that hour.

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Woodski

@foxriverat:  If you struggle getting those bolts out, and I don't suggest this as the first route, there are several options on alternator mounting for an SBC.  Many bracket options that use the cylinder head as the attachment point and the tension mechanism is also contained to the bracket.  Speed shops will have options to review.  Agree 100% on extraction methods noted above, LH drill bit.

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kwebster1

From multiple other applications and experience,  I would suggest not going the easy out route. I cant tell you how many times I've had easy outs break and make the job 10 fold harder. See if you can track down the size and pitch of the bolt and methodically drill and tap the threads. 

Edited by kwebster1

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foxriverat

I got the top bolt out. The bottom one must be stainless. I saw 2 spots where someone tried to drill off center. I was able to use a punch close to center and started to drill using oil I didn't get very deep before bit was toast. I ordered the new bracket today. It doesn't look like it even uses the bottom bolt. So will probably just leave it.

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cowwboy

Might also try using a dremel with a very small cutting blade or mill end bit to make a notch to use a flat head crew driver. 

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