Bad Day With Alternator Bracket

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MarcP

Tried to replace the alternator bracket on my M25 engine with the newer design. The good news was that the bracket was indeed broken and I didn't realize it. The bad news is that the bolt that goes through the bracket and ear of the gear housing appears to be rusted to the gear housing tab. I removed the nut from the back of the bolt but could still not turn the bolt. In fact I rounded the head of the bolt with vise grips and still can't get it free. Any ideas would be greatly appreciated. The bolt head is pretty mangled. Also the two studs at the front of the water tank on the port side appear to be siezed and I can't back them out. Getting low on ideas and thought I would ask the group before I give the work over to the yard to complete. Thanks in advance MarcP
 
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Allen

Drill

I hate to say it, but I'm guessing at this point your only option is to try to shape the bolt head so that something else can grasp it (a dremel tool can cut a notch in it for a screwdriver to try to turn it, for example). Let the bolt soak in something like WD-40 for a few days and see if she'll budge. If not, try to apply some heat with a butane torch (careful not to catch anything on fire!). If that doens't do the trick, then you're probably going to have to drill out the old bolt & get a new one. Good luck! Allen Schweitzer s/v Drambuie Hull #632
 
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R. Hodge

Alternator Bracket

Marc, I just did the same mod this last weekend on my C30. Although I didn't have your problems it was still a pain in the butt. I'd go with Allen on soaking the bolt with WD-40 or Liquid Wrench. You may be able to get your vice grips around the body of the bolt after that. Also since the nut is off you may be able to punch the bolt out from the back with a hammer and rod of some sort. I know there's not much room in there but it might be worth a try. As far as the studs go, if the threads are okay i'd just mount the new bracket using the old studs. That's what I did and I understand others have also. Good Luck, Ron
 
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MarcP

Studs Too Short

I'll give the WD 40 a try for a few days. I do have a dremel tool so i'll also cut the slot and see if I can get a screwdriver on it. Will probably have to be an offset screwdriver as there is not much room. As far as the water tank studs I have heard that quite a few people were able to use the old studs. In my case for some reason the studs are too short and there is not enough threads to get a nut on with the new bracket in place. MarcP
 
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John Visser

Liquid Wrench

I recommend LW instead of WD-40. I think WD-40 is way over-used and over-touted. Its actuall a apoor corrosion inhibitor and poor lube in the marine environment. It washes away quickly, and it washes away other lubes when applied. Heat is good for extracting studs. Have a fire ewxtinguisher at hand. I have a stud extractor, which is a cam-like tool that goes on a socket wrench. Works great, Sears has them. The stuck bolt - cut hte head off and use the stud extractor.
 
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