Broken Alternator Bolt

[Texas Sun Power]

TL;DR. What do I do about that broken bolt?

When try to replace my alternator, I feel like everything that could go wrong, did.

Steps	Result
Air filter box removal	Broken vacuum inlet
Power steering pump	Success
Bottom Alternator bolt	broken bolt into block
10mm electric removal	Stripped to sh:t, vice grips called in
Connector	Crumbles in my fingers.
Removing thru the bottom	Nope
Fan Shroud	More like shred and broken tabs (started that way)

What do I do about that broken bolt? Not a lot to grab.

 

[Patron100LC]

Here's a thread I stumbled upon and remembered it's around:

Alternator bracket help- Broken bolt🥺

My Cruiser is a 1999. I got it at auction few weeks back knowing it needed alternator, starter and radiator. I’ve been stumped with trying to remove broke bolt from the lower alternator bracket hole. I drilled it out enough to try using a extractor tool.. it also broke off in the hole! I’ve...

forum.ih8mud.com

Also, why there's NO LEAKS in your engine?? do you have oil in it?

 

[Texas Sun Power]

Also, why there's NO LEAKS in your engine?? do you have oil in it?

lol, you know, if there were leaks, this thing might not be so seized up!

 

[TahoeZ]

Tack-weld a nut on it.

 

[MountaineerLC]

Drill it out completely and run longer bolt through it with a nut on the back side. That’s how I repaired mine and it’s been fine for several years.

 

[excessive]

I'm sorry to report this to you, but I had the same issue. I tried numerous times to weld a nut onto the bolt ( probably tried 10 times) but it was just 100% frozen in there. I even tried heating it up red hot with an acetylene torch prior to welding the nut on. I also tried drilling, but what was left of the bolt was so mangled and hard as stone that I could not even get a drill bit started, the bit would just hit what was left of the mangled aluminum. I pretty much destroyed the surface of the oil pump doing so many attempts at getting that bolt out.
After all this i mad the difficult choice of replacing the perfectly good oil pump with a new OEM one. The good news - the oil pump is surprisingly affordable, probably because they never go bad. The bad news- it's an extremely involved job, i actually had the engine out , but it can be done with the engine in

 

[Texas Sun Power]

Thanks, let’s hope it doesn’t come to this.

 

[Malleus]

@Texas Sun Power : Don't drill» use a Dremel with a flex shaft and a carbide burr, smaller than the bolt diameter. You'll be done in less time than it takes to get the tool out, set it up and put it away after you're done.

I gave up drilling bolts out long ago.