Stuck on V-Belts: ALternator bolts frozen and tension bolt broken

[okyoureabeast]

I am nearly finished with my water pump replacement, but I am stuck on the belts.

The alternator bolts are completely frozen in place. I've heated and soaked them in penetrating oil.

I eventually got the bottom bolt to break free using a vice grip and mallet

How the heck do I get to the three bolts in the rear? I have the turbo in my way.

Also the bolt that adjusts the tension is broken. I feel as if this should be significantly easier than this appears to be.

[Fattyman]

If you have a 1985 300DT - 348,000 there are only 2 bolts holding the alternator in. You got the bottom one and there is one on top that holds the tension bracket to the block. Did you loosen the 17mm nut on the back side of the bracket that locks the tension bolt in place?

[okyoureabeast]

I loosened one 17mm bolt that is directly in front of the engine near the water pump and lower crankshaft.


If i'm laying underneath of my car there is a 2nd bolt that I loosened using my vice grips and a mallet.

How do I take care of this broken tension? The archives are a bit vague on this. It's broken exactly in the middle of the bolt.

[Fattyman]

There is a 17mm nut on the back side of the tension bracket that locks the tension nut in place. I'm lost without pictures.

[okyoureabeast]

I can see the bolt you're referring too, but there is no way I can get to it without removing the turbo.

Crap.

[Fattyman]

Something is not right here. Can you get a flex ratchet on the nut facing the firewall on the back side of the alternator bracket? The turbo should not be an issue.

[Diesel911]

I am not sure if this is the Alternator Bracket that you have. It is the same type as on my 84 300D.

The yellow Arrow points to the 17mm Bolt that needs to be loosend in before you try to move the Tensioner.

[Fattyman]

Now your talking (showing).

[okyoureabeast]

Ahh! That makes sense now.

Figures right after I completely sear off the rest of the tension bolt arm

I don't own an flex wratchet sadly. I'm trying to figure out what the hell can get back there.

This is absolutely miserable. Why did they have to make this so difficult when rusted

[funola]

Originally Posted by okyoureabeast

Ahh! That makes sense now.

Figures right after I completely sear off the rest of the tension bolt arm

I don't own an flex wratchet sadly. I'm trying to figure out what the hell can get back there.

This is absolutely miserable. Why did they have to make this so difficult when rusted

I used a 3/8 breaker bar with a 16" pipe for extra leverage and a 17 mm socket to break free the bolts then used a ratchet.

[okyoureabeast]

Sorry to revive an old thread, but I got around to taking picture of the new tension bolt. The fix is incredibly strong. Germans like to make everything unnecessarily complicated

I've attached it below for reference to any other poor souls who cursed as much as me. Total cost of everything was $4.15

[Diesel911]

When I removed my Alternator I removed the 2 bolts that held it to the Block and took the Alternator out with the Bracket still on the Alternator.

I did that because not realize the 17mm Bolt needed to be loosened and it was the only way I fitured to remove it.

If the skinny threaded part of the Tensioner is busted off you can replace it at over $40 each or find another way to tension the Belts and hold the Alternator in place while you lock down the 17mm Nut.

If you decide to replace the Tensioner Bolt but are unable to use to origiona Tensioner Nut (I have not seen any part places selling the correct nuts) you can do as this guy in the other Forum did.
He used 1 regular nut, 1 self locking Nylock type nut and a washer (he bought a new Tensioner Bolt).

[okyoureabeast]

Thanks for the help guys. I finally got the bolt off. With much celebrated fan fare.

The entire bolt is entirely unusable. I am going to have to have to replace this.

There was a post somewhere in the archives about a guy making a cheap one rather then a MB replacement.

Time to start searching.

[layback40]

Originally Posted by okyoureabeast

Thanks for the help guys. I finally got the bolt off. With much celebrated fan fare.

The entire bolt is entirely unusable. I am going to have to have to replace this.

There was a post somewhere in the archives about a guy making a cheap one rather then a MB replacement.

Time to start searching.

I can see a visit to a junk yard in your future!!

[charmalu]

There was a thread some while back, where the guy buggered up the tentioner bolt. so instead of buying a new $40 bolt, he cut off the small rod that fits into the bolt head. He used an "Eye" bolt with a machine thread on the other end. slip the long bolt through the "Eye" end, then the threaded end will fit in the adjustment end with a nut and washer.

Charlie