Hello, I have been browsing the forums for a while and decided today was the day I join and see if I can contribute, or atleast give some of you more experienced guys some laughs from my mistakes.

91 Ranger, 2.3L, 5 Speed, ~160k.

I had taken off for work after letting the truck warm up for 10-15 minutes. I pulled onto the road and 2 miles later I lose all power, the engine would turn over but not start. We pushed the truck back to the driveway where the detective work began.

I suspected the alternator, so I decided to have the alternator tested. This is where the problem began. I don't think the alternator or the tensioner pulley bolts had ever been touched since the truck rolled off the floor. So I soaked up the bolts with brake cleaner (Someone told me it penetrates better than WD40). I soaked it up for a good 5 days, trying to crack it loose everyday. Finally I grew tired of being gentle with the bolts and used a persuasion bar. The first bolt loosened, although the second bolt I thought was loosening turned right off leaving a threaded stub sticking out. Now I have a broken bolt in the power steering pump.

Do you think it would be easier to replace the entire pump or try and drill out the bolt? I am not sure of bolt removal options other than ez-out or drill and tap. The same guy who fed me the line about the brake cleaner also said there was some sort of threaded bolt you could screw on to a broken bolt and loosened it, ever heard of anything like this? The bolt only sticks out about 1/4".

Here are some pictures of the broken bolt and the other pulley that hadn't been removed yet. Which after soaking up with WD40 for about 3 days finally cracked loose.

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Also, the alternator failed at 3 different store and after replacing with a new one didn't solve the problem. When it failed to start after replacement, I peeked behind the timing belt cover and was able to pull the belt out. Now on to the next problem.

Thanks!

First and foremost, welcome, I'm a Newb myself



Brake cleaner to loosen bolts? Yea right, it'll make them brittle over time that's about it. I use PB blaster, some use WD40, wahtever works.

To get the bolt out: I'd say weld a screwdriver to it likea wrench and twist it on out. Done it many times no problem.

If that's not an option there's a socket with a head that looks like 6 twisted half moons rather than 6 flat sides (think about it). I'm not sure what there called but they are specifically designed for removing f*d bolt heads, and if you sacrafice a really small one and hammer it on there, it WILL come off. I've used them on sheared driveshaft bolts with success.

Good luck

Saul

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'83 Ford Ranger 2.3L 4Spd, Dual Tanks, 195/60R15's, Welded Rear End TOTALLED AT 483,211 MILES