Tensioner Bolt Broken Off? Here’s What You Can Do
When working with heavy machinery, it’s not uncommon to encounter a broken tensioner bolt. This issue can be particularly frustrating when the bolt snaps off inside the engine block or other components, making it difficult to remove.
We discuss what you can do when faced with a tensioner bolt that broke off and how to prevent this problem in the future.
What Causes a Tensioner Bolt to Break?
Tensioner bolts are subjected to significant stress and strain, especially in belt systems like the serpentine belt or timing belt. These bolts are responsible for maintaining proper tension on the belt, ensuring that it drives various components such as alternators, power steering pumps, and water pumps effectively.
Several factors can contribute to a tensioner bolt breaking, including:
- Overtightening – Applying too much torque when tightening the bolt can cause it to weaken and eventually break.
- Under-tightening – Insufficient torque can cause the bolt to loosen over time, leading to increased stress and potential breakage.
- Corrosion – Exposure to moisture and other corrosive elements can weaken the bolt over time.
- Fatigue – Repeated stress cycles can cause the bolt to develop small cracks, leading to failure.
- Manufacturing defects – In rare cases, a defective bolt may break prematurely.
How Can You Remove a Broken Tensioner Bolt?
When a tensioner bolt breaks off, it can be a challenge to remove, especially if it’s stuck in the engine block or other components. Here are a few methods you can try:
Using an Extractor
A bolt extractor is a specialized tool designed to remove broken bolts. It works by gripping the broken bolt and turning it counterclockwise to remove it. To use an extractor, follow these steps:
- Drill a small hole into the center of the broken bolt using a drill bit slightly smaller than the bolt’s diameter.
- Insert the extractor into the hole and tap it gently with a hammer to ensure a snug fit.
- Using a wrench or socket, turn the extractor counterclockwise to remove the broken bolt.
Drilling and Retapping
If the extractor method doesn’t work, you may need to drill out the broken bolt and retap the hole. This process involves the following steps:
- Using a drill bit slightly smaller than the bolt’s diameter, drill into the center of the broken bolt.
- Gradually increase the drill bit size until you’ve drilled through the entire bolt.
- Use a tap to create new threads in the hole, ensuring that they match the original bolt’s size and pitch.
- Install a new bolt and tighten it to the proper torque specs.
Using a Right-Angle Drill
In some cases, there may not be enough room to use a standard drill to remove the broken bolt. In these situations, a right-angle drill can be a valuable tool. This type of drill features a compact head that allows you to access tight spaces, such as the area around the serpentine belt or timing belt.
Preventing Tensioner Bolt Breakage
To minimize the risk of a tensioner bolt breaking, consider the following tips:
- Safety first. Wear protective gear, such as safety glasses and gloves, and ensure the area is well-ventilated.
- Always adhere to the manufacturer’s recommended torque for the tensioner bolt. Using a torque wrench or bolt tensioner is crucial for achieving the precise tightening force.
- Use a high-quality, high-grade bolt (like grade 8) designed for high-stress applications.
- Include a visual inspection of the tensioner bolt and surrounding components as part of routine maintenance. Look for signs of wear, corrosion, or cracks.
- Apply a thin layer of anti-seize compound to the bolt threads to prevent corrosion and galling, which can contribute to bolt failure.
- When replacing the serpentine belt or timing belt, always replace the tensioner and any associated hardware, such as the tensioner pulley and mounting bolt.
- If the broken bolt is in a difficult-to-access location or if the machinery is complex, seek professional assistance to avoid further damage.
ALLTORC’s Solutions for Tensioner Bolt Issues
At ALLTORC, we understand the challenges associated with broken tensioner bolts. That’s why we offer a range of hydraulic bolt tensioners capable of applying precise, controlled tension to bolts, minimizing the risk of overtightening and breakage in the first place. In addition, we also offer tool repair and calibration services to ensure your tensioners and torque wrenches stay in the best shape.
Down But Not Out: Fixing Broken Tensioner Bolts
Dealing with a broken tensioner bolt can be frustrating, but with the right tools and techniques, it can be solved. By understanding the causes of tensioner bolt breakage and the methods for removing broken bolts, you can minimize downtime and keep your equipment running smoothly.
If you’re in need of high-quality tensioners and wrenches, ALLTORC is here to help. With our extensive selection of industrial-grade torque and tension equipment, we can provide the solutions you need to tackle even the most challenging tensioner bolt issues.
Contact us today to learn more about how we can help keep your operations running smoothly.