I was just under car again. Distance between outside of bracket's "ears" IS, as you say, 120mm. (Don't know how I got that wrong first time!)

The front ear is threaded, so presumably there never was a nut. I tried screwing in M10 bolts (1.25 and 1.5 pitch) from front end, but they would not start. An M8 bolt is very loose, so it must be an M10 thread. I can see thread from front, but don't know if inner part is still good. If bad, may explain bolt falling out.

A longer bolt with a nut is an option, but hard to get in there and drill out the front "ear". It would need to be about 130mm. Maybe a 5" 3/8 bolt could be found more easily.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Thanks for offer. Appreciate it!

Can you measure bolts? Are they ~120mm type without nut? or longer with nut? Is diameter 10mm?

PS: Talking lower bolt here.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Yes it is 10mm, and measures 125mm long. I imagine 120mm will work.

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


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Sanden Instalation Guide (post 11):
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That sounds good. I like the 125mm because it may allow me to get a nut on and not rely on the aluminum threads.

I will send you a pm with address. If you could ship me one by First Class mail (to keep costs down) that would be great!

Graham

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Rich has a bolt on way to me! Thanks!

Today, I raised alternator out of bracket and threaded a short M10x1.5 into the forward ear. Thread is still good. Bolt got tight when it got near end. Might have to chase thread if bolt is 124mm long. Then add a locknut.

To get at upper bolts, I removed air cleaner. Found that my repair on the bracket had broken again. May try and get a new bracket. It was probably the broken bracket that was making the noise described at beginning of this thread!

I removing air cleaner bracket, I remembered a previous problem Where the lower bracket bolt screws into the block, the thread had stripped. What I had done back then, was put in a longer bolt - about 4 or 5 threads were holding - used JB-Weld on stripped section. Anyone had this problem? How did you fix it? Helicoil?

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Thanks to Rollguy, I received a bolt yesterday and installed it today.

Not that easy lying on back for 78 yr old! Ground short taper nose on bolt so it would self center in alternator bracket. Had to use a couple of long 1/2" extensions with 17mm socket, then tap with hammer from rear end to get bolt to enter the alternator bracket. Then I was able to push it it as far as second ear while using big screwdriver to wiggle the alt bracket. Then used the long extensions again with ratchet while jiggling the bracket until bolt got started in thread. (alt bracket hole is oversize, probably due to wear while original bolt was working its way out.

Finally got bolt all way in and protruding enough for a nut with Loctite to hopefully keep it there.

Now have to go repair my air cleaner bracket. I ordered a new one, vendor accepted my Paypal payment but failed to tell me that they did not have any brackets in stock. Didn't even confirm order! Anyway, I finally got a refund and am $50 better off

Thanks for the support!

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Today while driving, something didn't sound quite right. I thought it might have been noise from drive belts. Had a look, and saw that the outer belt for the alternator had come right off and was now inside out and touching the fan (that was the noise)!

I know I had the belt on and properly tensioned after I installed the pivot bolt.

I was going to see if I could get a new set of belts and install them. I probably even have a slightly used set in shop. But then, I thought - how the heck did that outer belt come off?

One thing I noticed when I put in the pivot bolt, was that the hole in the alternator aluminum casting was worn and the bolt was a very loose fit. Probably got that way as old bolt gradually wiggled it's way out.

So thinking that perhaps the alternator is tilted and the shaft not parallel with the engine drive shaft. This could make outer belt too long and both belts improperly aligned.

The alternator still works well, but maybe answer is to replace it. Otherwise I would have to try and sleeve the mounting hole.

It's frigging cold here, so may have to get a local shop to do the job. Or leave it until next Spring and see if I can get one new belt back on temporarily (Car will be off road from Jan-April anyway)

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

It should be fairly obvious of the alternator's pulley isn't properly aligned .

If you use non German V belts often they're 1/4" or more different even with the same part # ~ forget about Gates Et. al.'s "matched sets" ~ they're a joke .

You _can_ do this even in the cold .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

I learned the hard way to only buy the Conti belts and that is what I have on car. I bought Gates once and then had to throw them out and go to dealer. I will buy new set of belts from dealer on Monday. The alt belts come as a matched set and from what I recall, were less expensive that the Gates from auto store.

According to EPC, the MB part number for alt/pump belt set is 0049973992. 9.5x1035. (Same as I now have)

EPC has a long list of part numbers for the PS belt. All same length 12.5x1145. Even with VIN, it doesn't say which part number to use. From one vendor site and first number on epc looks like it is 0049979992.

-7C at present. Might start removing some stuff in engine bay. Or, might reinstall the loose belt and see if I can see why it came off.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Didn't get far. Almost got frostbite, even in garage. Noticed that second belt that is still on is not very tight. Thinking maybe belt adjuster slipped or something and belts loosened. The belt that came off is twisted and being so cold doesn't want to reform to proper shape. I may try putting heater under car and maybe use a heatgun on belt. Then try re-installing and tensioning. If I can get car on road for next 4 weeks, that is all I need. Then install new alternator in Spring when I get back. Otherwise it may go to local shop. 2 hrs labor should do it Couple hundred bucks?

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

Jeezo-Peezo Grahm ;

You're making me remember my youth in Rural New England fixing old tractors and rusted out pickup trucks in the snow.... .

Anyway, if the belt(s) is/are tight enough to make a squeak sound when you force the pully to turn they're fine, don't sweat one being slightly looser, as I said before ; NOT AVAILABLE in matched sets no matter what B.S. the Dealer says .

If the battery shows 13.9 or better VDC once it's started (with everything turns off) the alternator and belts are fine .

If less voltage, first check at the back of the alternator to see what it's putting out, most non BOSCH branded regulators/brush holders don't ever charge above 13.4 VDC, why I only accept BOSCH brand regulators .

If the dash light is out and it's starting O.K. in the cold, stop before you do get frostbit ~ I remember frost bitten ears, not much fun .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

See my posts in other thread about 55/65 alternators. Found my suspicion about oval hole in alternator foot was correct. No point putting belts on old alternator. New one here soon anyway. I don't know if they are actually matched, but alt belts from MBCanada come in packaged pairs.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

To conclude this thread, picture of the pivot hole in the alternator foot. Same shape all way through. When original bolt worked it's way out, it must have sawed the oval shape.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

? So, it's all done now ? .

I've been reading the various alternator amperage, v belt and bolt threads and of course, SWMBO's 300TD's charge lamp isn't going off the instant the engine starts anymore, I guess I'll have to change it out for a spare '65 A. unit pretty soon .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

No, just moved "project" to the 55/65A thread. Still waiting for Alternator. We have had a mail strike and Amazon use them for shipping sometimes.

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5