This is not a fun job. The studs are a really tight fit and they are a grade 10.9 stud which makes them hard to drill. You will probably need good drill bits, a right angle drill, variable speed, EZ outs and a torch, (oxy/acetylene). If you do have to completely drill out the studs to the threads, you will need a heli-coil. High strength is needed here. There is not enough material in the case for oversized studs or solid inserts. As for how deep to drill, start with a small drill and you will feel where the stud ends. Replacement hardware here must be at least grade 10.9 including the washers. The wrong nuts are what probably cuased the failure in the first place. Check the bracket carefully. These are also prone to cracking. Dennis -----Original Message----- From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Paul Guzyk Sent: Thursday, February 10, 2005 8:47 PM To: vanagon@GERRY.VANAGON.COM Subject: Broken bolts on 1.9L lower alternator bracket.... On my 84 Vanagon the two studs that hold the lower alternator bracket to the engine block have broken off (see Bentley page 27.15) ....and of course they've broken off behind the bracket aka inside the engine block. :( In order to get access to the holes in the block I removed the alternator, the metal coolant cross pipe from water pump housing to the passenger side head then I removed the oil filler tube from the bottom of the block. (The oil filler tube is held on by two 13mm nuts, one easy to get at, one not so easy). Tomorrow I intend to drill out the two broken studs then re-tap them with the standard 8mm threads. How far into the block can I drill? If I go too far I assume I will break the water jacket? That wouldn't be fun... Anyone have a better solution? If you've rigged up some other way to hold the lower alt bracket please post photos.... -Paul |
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