Hello Folks,
Hope all your 240 models are running great.

1) Broken Tension Bolt for Alternator where tension bar attaches to engine block.
2) Used an "easy out"...After drilling a hole in the original stuck bolt 1/4 inch inside the original hole.
3) Easy out broke off in the drilled out bolt.
4) Unable to drill a hole in the easy out because that metal is undrillable.
5) Drilled holes around the broken bolt in an attempt to remove the bolt and its new partner the easy out.
6) After making multiple holes around the bolt from the front and the left side I was able to remove the broken easy out then the original broken bolt.
7) realized that there were still threads at the very end of the original hole.
8) I used a "grade 8" bolt to reattach the tension bar.
9) after a week or so I realized that the "grade 8" bolt broke at where the surviving threads were, at about an inch in the original hole.
10) now I have a big odd shaped hole with a broken grade 8 bolt at the very end.

The Plan.
1) use JD WELD to attach a "grade 8" bolt in reverse, with the threads sticking out and the head of the bolt in the hole after I grind the head down to fit in the hole. Then I will have the threads sticking out where I will be able to attach the tension bar bushing with a new nut.


Does this sound like maybe the best possible solution?
I cannot rethread the original hole because it is a big odd shaped cave now.

And advice is appreciated. After you sit there shaking your head.

Joseph Segura in New Mexico.