The bushing at the block for the pivot.

These things are problematic - I've seen a few that the bolt breaks off because of the poor design and mount. You're basically bolting the accessory bushing to the block (1/3 of it with no support - towards the tension...brilliant), then the bracket is held on by just the pressed in bushing. UFB.

Does anyone know the reason behind having to have a bushing at the block? Has anyone ever used one of the solid-aluminum bushings instead? That would be better (a welded washer that holds the actual bracket to the block would be even better) - but was wondering why they feel the need for a cushion there, or if it matters.

Yeah Chris I think people have had problems with this, and I suspect a good bit of their poor experiences were due to their or a previous fixer's lack of understanding. Perhaps there is room for criticism of the design, which is what I gather you are looking for, using terms like "poor design, problematic, brilliant, (sarcastically) UFB (is that a TB term?)" and I would agree the whole shebang is a bit of a thorn in the side of an otherwise maintainable 240 even without the tensioner and jack screw ... but you see what they were up against if you follow the evolution of that three-pulley arrangement needing two belts from the originally tiny alternators needed in the 70's. Fixed it on the 7/9 of course.

To add to this, the drawings are little help to explain how the bushing expands to grab the inside of the sleeve when the bolt is tightened, and confusion over this and the placement of the bushing results in M8 bolts breaking out the cast iron and the rusty M6 jackscrew snapping in the lock.

Anyhow, when you figure it out, let us all know, because no one I've heard yet has returned from poly or solid aluminum solutions to say they were happy for many years and miles afterward.


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Art Benstein near Baltimore

Jokes about German sausage are the wurst.

I wouldn't consider poly - its great for locating but not for load. As with other accessory bushings, I'll use the OE rubber first.

Take any of these off of any 240 - serviced or not - and you'll see the uneven stress on the bushing - it sits on an edge, being pulled towards the side of less-little support. It flexes and stresses that bolt. Every one that breaks, does so in the same way and place. A large washer at the block would at least give it support on a complete surface to extremely limit or eliminate the lateral stress. I would have liked to see something that holds the bracket to the block, than just friction from a rubber bushing. You lose your PS, you drive it home with a workout. You lose your alternator, you're being towed. So yeah....sarcasm applies.

Never mind. Got it figured. No vibration and rock solid mount.

Thanks.

>Never mind. Got it figured. No vibration and rock solid mount.

So you tried the large washer against the block and at this point at least feel that it is a definite improvement?

Randy

I machined a new sleeve and bracket. Sits like it should have with zero flex or stress.

How about a picture!

Art
I don't think I have ever seen #14 in the diagram do you know what size the part is?
Thanks
Dan

Dan, I don't think I've seen this thing either. The line drawings are and have always been poor even for parts identification, so I don't make much of the shape differences I notice.

I think Chris is looking at the block to support the rubber, but when I put new parts in, I see the block only has to provide enough surface to support the sleeve inside -- which looks like something #14 could do as well. Any lateral shove on that M8 bolt can't be offset by mere rubber.

The other thought I had, in case those things existed, but fell out long before our ownership, is #14 could be what expands the rubber. Cup shape. Just a guess from a designer's point of view.
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Art Benstein near Baltimore

I stayed up all night to see where the sun went, and then it dawned on me.

Art
That's good to know, I've had 6 240's and pulled numerous alternators and never ran across one!
Thanks
Dan

Let me post the link to the TB version of this thread. Currently it has no responses, but there's a wealth of experience out there:

http://forums.turbobricks.com/showthread.php?t=314782
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Art Benstein near Baltimore

This girl said she recognized me from the vegetarian club, but I'd never met herbivore.