A Site for the Volvo 240

More alternator troubles

Added on by Chris Quill.

So, the alternator worked loose again. The belt flopped around and caused the bolt for the bracket to shear off in the block.

 Sheared alternator adjuster bold in the block B23.

Sheared alternator adjuster bold in the block B23.

So I did the weld-a-nut trick and it worked pretty well. I learned that you need to turn the welder all the way up to max. The block is to big of a heat sink and it wouldn't get any penetration into the broken shaft. Once I turned it up to 'D' (on the 12th try), it worked perfectly.

 Welded nut.

Welded nut.

You will notice that I have a piece of welding cloth. I would consider that essential to prevent your grease caked flammable harness from catching fire.

I bolted on my last bracket, tightened everything up and I'm back on the road. I also learned that a 5/16 fender washer perfectly matches both the bolt size and the bushing diameter. It helped shore up the rubber a bit and compress everything nicely.