ThisIsMe

Wife's 2002 Mercedes needed a new voltage regulator. Its like a 20-30 minute job. Except when I do it. One of the alternator bolts was the hardest bolt I have ever unscrewed. I got it about an inch out before it broke. Once I finally got the alternator out I have been trying to take the rest of the bolt out with no success (there is a little over and inch worth to grab onto). Tried powering it out with some vice grips, nothing. The two nut method, nothing.
I know there are some other ways like drilling it out but the car is in a parking lot 30 minutes away so I don't have normal access to it.
Does anyone here have any ideas? This should have been so simple and I would hate to take it to the shop.

drtyjrzy

did you try "open and shut"? or "pb blaster" to free up the threads? if not try that, as for getting a grip on the bolt now, I would try and get a nut on the end and drill a small self tapping screw through the nut and bolt, cut off both ends of the screw and get a socket on the nut. if that doesn't work you will prob need to drill a hole down the length of the bolt and use an extractor (reverse thread bolt with a square shaft). good luck bro.

drtyjrzy

sorry. didn't specify that u will need to drill a pilot hole for the self tapping screw.

ThisIsMe

I have tried pb blaster but I think I will try some more and work the bolt in and out if I can move it.

Carsy

Good idea. Try lots of "Penatrene" which is a light volatile penetrating liquid ( petroleum based )which lubricates & frees up threads.

Back wards & forwards lots of times adding the penetrene to the exposed thread to wash out any damaged metal & dirt.

Let us know how you go.