383 alternator pivot bolt broke! Now what?

[DartGTDan]

My buddy's '63 Dodge 440 (383 engine) was about to receive a 1-wire alternator today. We popped the hood, disconnected the battery and put the wrench on the pivot bolt and it was loose. Pulled the bolt out of the spacers and noticed the threaded end of the bolt was broken. WTF!!!! It appears there is about 1/2" of the bolt stuck in the head. Now what?

 

[4spdragtop]

Left handed drill bit

 

[Tooljunkie]

Some careful drilling.
Usually the bolt can be persuaded out with an easy out, i prefer a torx bit. I find a drill bit just a tad smaller than the torx.
Drive it in and with some luck it comes right out. Always,always use a torx small enough that if it breaks you can drill around it, or if it slips you can go up a size.

 

[Tooljunkie]

Also it’s 3/8” coarse thread in cast iron. Lots to work with there.
Compared to 8mm in aluminum heads, where i have had to deal with them a lot. I mean a lot.

 

[72Dart6pack]

1/2 inch? That's more than enough. I'd try PB blaster & some heat. Look up the candle wax trick. That works awesome too.

 

[67Dart273]

If worse comes to worst, swap the heads side to side

 

[RAT ROD AL]

Here's another option.

HeliCoil 5521-6 - Thread Repair Kit 3/8-16 Inch Coarse
Thread Repair Kit

• 
  features:
• Includes 12 inserts, complete instructions, Heli-Coil tap and installation tool
• Used for repairing tapped holes
• 12 inserts. Drill size: 25/64
• These Heli-Coil inserts work in any part or material--aluminum, magnesium, cast iron, bronze
• Damaged threads can be restored to better-than-new condition in spark plug ports, carburetor fuel inlets, transmission housings, oil drain plugs, exhaust and intake manifolds, head bolt holes, brake calipers, and more

Manufacturer: HeliCoil Our Part No: 5521-6
Our Inventory Status: available for order

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