TIMING BELT PULLEY BOLT BROKE OFF DODGE 3.5L

Asked by Guru1P92M Sep 20, 2019 at 07:55 PM about the 1997 Dodge Intrepid FWD

Question type: Maintenance & Repair

hello, working on a dodge intrepid 3.5l timing belt tensioner bolt broke off flush with the aluminum housing. what is the best way to remove broken bolt or is there another way. or is the mount replaceable? mount part number is 45565 or 4556511. is it possible to remove the bolt? tried to cut a groove in bolt but it did not work. not enough metal sticking out

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KenF answered 5 years ago

Have you tried any of the bolt extractors on the market? Another method to extract broken bolts is to weld something to the stub that lets you get a grip on it. An old school method is to slag it out but that's not appropriate for an aluminum block. Keep in mind it broke in the first place because it's probably rusted in there, so use some heat/cold & penetrating oils to break that bond when trying to extract it.

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Guru1P92M answered 5 years ago

yeah, i was hoping someone had a magical solution. i will try to drill and extract. if the bolt is too hard i will try the weld method. bolt snapped because the pulley bearing broke apart. i assume the pieces of the pulley, ball bearings and washer got wedged under the belt and snapped the bolt. ill keep you posted. thanks for your input.

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