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Big bang! --> Tensioner Stud Snapped

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ibruceuk:
Just happily driving along today and suddenly and almighty bang and I get the battery light on and I have Geoff Capes fighting me trying to turn the steering.

It was a worryingly loud bang.  So I open the bonnet and I see the aux belt flapping and I'm sure something was missing.

Sure enough the whole tensioner assembly was missing.  It seems the stud snapped sending it flying into the viscous fan.  So it managed to smash the fan cowling to pieces and also remove a number of blades from the fan. :(

I managed to bodge up a belt with a bit of flex soldered into a loop to drive the water pump so I could get home.

I've got the broken stud out of the tensioner, but the rest is snapped just below the surface of whatever it screws into.

Any ideas on how I can remove the snapped stud from the engine bit, as it doesn't seem to want to budge.

Mud-muncher1:
Drill and and re thread the hole, well thats what i'd do but others might do it differently



Jav.

ibruceuk:
Yeah that's what I thought.  I'm gonna give it a go with a Dremel first to try and cut a slot in it and use a screw driver to turn it out.  In theory it shouldn't be too tight with it being snapped!

The whole water pump and PAS pump and alternator assembly has to come off to get at it to be able to drill it. :(

peasey:
Before you get the dremmel out try turning it out with a center punch and a hammer,punch it hard on one side with the punch and tap it round i have seen some big old bolts come out like that and the vibration helps to loosen the thread,other than that it drill and tap time.

Chris Putt:
Tack a nut on with a welder?

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