stripped idler pulley threads...help please!

hockeyplayer · 08-31-2015, 06:21 PM

Ok guys, I went tonight to replace my serpentine belt, tensioner and idler pulley with a kit I got from Pelican. When I removed the idler pulley bolt it seemed like it was really over torqued. Sure enough, there were metal shavings in the bolt hole and I cleaned them out thoroughly. Used a shop vac to get all the rest of that crap out of there...but here is my issue.

I can't get the new bolt to tighten up...the threads in the alternator are obviously stripped out. What are my options??? I've never used any type of tap/die or helicoil or anything like that, so what would you guys recommend?

Also, am I going to need to remove the alternator to fully fix this or can it stay in the vehicle?

I'm trying not to stress out here....

hockeyplayer · 08-31-2015, 07:07 PM

well I just decided to go for it with some JB Weld....we'll see what happens...gonna let it sit overnight

The Cleaner · 08-31-2015, 07:14 PM

If you can't get a drill to the hole your best bet is to hope there is enough material there to re-tap the hole. You will still need about 8 inches of room to do that. I think the reality is you will need to get enough room for a drill and thats probably going to require removing everything in front of the hole.

hockeyplayer · 08-31-2015, 07:40 PM

Quote:

Originally Posted by The Cleaner

If you can't get a drill to the hole your best bet is to hope there is enough material there to re-tap the hole. You will still need about 8 inches of room to do that. I think the reality is you will need to get enough room for a drill and thats probably going to require removing everything in front of the hole.

Thanks. Yes, I think you are right but I was really trying to avoid taking out the alternator. If the JB Weld doesn't hold I guess I'll go that route.

Efthreeoh · 08-31-2015, 09:00 PM

Helicoil is your best bet; that is exactly what the are designed for. Get one and follow the instructions. JB Weld will not hold.

jin · 08-31-2015, 09:08 PM

Personally I wouldnt be relying on JB Weld to keep the pulley in place. If it came loose who knows what damage could occur. I would hand tap it.

hockeyplayer · 09-01-2015, 08:41 AM

Thanks guys but I already did the JB weld and installed the new belt/tensioner this morning. So far so good, but I am probably going to call my Indy shop today to ask what they might recommend for a long term fix. I may end up taking it to them for a helicoil or Timesert repair.

1QuikWS6 · 09-01-2015, 03:57 PM

As mentioned above - long term fix is to remove alternator & install Helicoil

hockeyplayer · 09-02-2015, 09:42 AM

Quote:

Originally Posted by 1QuikWS6

As mentioned above - long term fix is to remove alternator & install Helicoil

Yep! Actually called my indy yesterday and I'm going to remove the alternator tonight & take it to them so they can put a helicoil in it for me.

chi2410 · 09-02-2015, 08:15 PM

helicoil is very easy to use, just read the instructions and in the future if you need to use it, then you know how, that way you don't have to pay to another person to do the job/ safe money. or check some videos in youtube / how to use helicoil that help a lot, good luck.

anujkch@gmail.com · 06-08-2020, 12:28 AM

I am having the same issue where the threads in alternator are broken and I plan to go the Helicoil route. But my question is which helicoil kit do I need to go for? As there are multiple sizes. Also, what is the bolt size i.e. is it 10x1.5 or 10x1.25 , 8x1.25 etc. I want to learn what is the exact size of bolt and what helicoil should I buy and use? Also what should be the length of thread insert. Is it 40 or 10 will do. Does it have to be Aluminium coil?

smass · 06-08-2020, 07:41 AM

Quote:

Originally Posted by anujkch@gmail.com

I am having the same issue where the threads in alternator are broken and I plan to go the Helicoil route. But my question is which helicoil kit do I need to go for? As there are multiple sizes. Also, what is the bolt size i.e. is it 10x1.5 or 10x1.25 , 8x1.25 etc. I want to learn what is the exact size of bolt and what helicoil should I buy and use? Also what should be the length of thread insert. Is it 40 or 10 will do. Does it have to be Aluminium coil?

Also, consider getting a used alternator. They can be under $20 from local salvage yards. They don't go bad often so they are not in demand. Just use new bolts to reinstall.

Efthreeoh · 06-09-2020, 01:57 PM

Quote:

Originally Posted by anujkch@gmail.com

I am having the same issue where the threads in alternator are broken and I plan to go the Helicoil route. But my question is which helicoil kit do I need to go for? As there are multiple sizes. Also, what is the bolt size i.e. is it 10x1.5 or 10x1.25 , 8x1.25 etc. I want to learn what is the exact size of bolt and what helicoil should I buy and use? Also what should be the length of thread insert. Is it 40 or 10 will do. Does it have to be Aluminium coil?

Go to boltdepot.com. You can learn all about bolt sizes, thread count/thread pitch and grades of hardness. They have good educational materials to review.

Osdp1621 · 12-18-2022, 08:29 PM

Did the JB weld work on taking the pulley out I’m having a similar problem of a stripped bolt on my idler pulley

Bmw1939 · 12-18-2022, 10:15 PM

Helicoil is your friend.

08-31-2015, 06:21 PM	#1
hockeyplayer Captain 74 Rep 776 Posts Drives: 2006 325i, 2006 325xi Join Date: Oct 2011 Location: NC iTrader: (0)	stripped idler pulley threads...help please! Ok guys, I went tonight to replace my serpentine belt, tensioner and idler pulley with a kit I got from Pelican. When I removed the idler pulley bolt it seemed like it was really over torqued. Sure enough, there were metal shavings in the bolt hole and I cleaned them out thoroughly. Used a shop vac to get all the rest of that crap out of there...but here is my issue. I can't get the new bolt to tighten up...the threads in the alternator are obviously stripped out. What are my options??? I've never used any type of tap/die or helicoil or anything like that, so what would you guys recommend? Also, am I going to need to remove the alternator to fully fix this or can it stay in the vehicle? I'm trying not to stress out here....
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08-31-2015, 07:07 PM	#2
hockeyplayer Captain 74 Rep 776 Posts Drives: 2006 325i, 2006 325xi Join Date: Oct 2011 Location: NC iTrader: (0)	well I just decided to go for it with some JB Weld....we'll see what happens...gonna let it sit overnight
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08-31-2015, 07:14 PM	#3
The Cleaner Thats all you need to know. 43 Rep 1,188 Posts Drives: 2018 M2 , 2016 X5 Join Date: Dec 2006 Location: Nor Cal iTrader: (2)	If you can't get a drill to the hole your best bet is to hope there is enough material there to re-tap the hole. You will still need about 8 inches of room to do that. I think the reality is you will need to get enough room for a drill and thats probably going to require removing everything in front of the hole. __________________ - M2 2018 LBB / Black - X5 F15 2016 Mineral White / Black 1981 Delorean number 6489
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08-31-2015, 09:00 PM	#5
Efthreeoh General 17309 Rep 18,733 Posts Drives: The E90 + Z4 Coupe & Z3 R'ster Join Date: May 2012 Location: Virginia iTrader: (0)	Helicoil is your best bet; that is exactly what the are designed for. Get one and follow the instructions. JB Weld will not hold. __________________ A manual transmission can be set to "comfort", "sport", and "track" modes simply by the technique and speed at which you shift it; it doesn't need "modes", modes are for manumatics that try to behave like a real 3-pedal manual transmission. If you can money-shift it, it's a manual transmission. "Yeah, but NO ONE puts an automatic trans shift knob on a manual transmission."
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08-31-2015, 09:08 PM	#6
jin Second Lieutenant 74 Rep 252 Posts Drives: 2007 E90 335i Join Date: Jan 2015 Location: NZ iTrader: (2)	Personally I wouldnt be relying on JB Weld to keep the pulley in place. If it came loose who knows what damage could occur. I would hand tap it.
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09-01-2015, 08:41 AM	#7
hockeyplayer Captain 74 Rep 776 Posts Drives: 2006 325i, 2006 325xi Join Date: Oct 2011 Location: NC iTrader: (0)	Thanks guys but I already did the JB weld and installed the new belt/tensioner this morning. So far so good, but I am probably going to call my Indy shop today to ask what they might recommend for a long term fix. I may end up taking it to them for a helicoil or Timesert repair.
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09-01-2015, 03:57 PM	#8
1QuikWS6 No 55mph 1621 Rep 8,476 Posts Drives: F32 435ix MSport Join Date: Jul 2009 Location: Blitzburgh, PA iTrader: (113) Garage List 2022 BMW M440ix Vert [0.00] 2015 BMW 435ix MSport [0.00] 2000 Pontiac Trans Am [0.00]	As mentioned above - long term fix is to remove alternator & install Helicoil __________________ F32 435ix//MGM//M Sport-Prem-Tech-Driver Assist-Lighting-Cold Weather-Dyn Handling Pkgs//M4 Black Lthr Int w/M4 Alum Blade Trim//HK w/Bavsound Stg3//763M//M4 Euro LCI Tails//M4 Mirrors w/CF Covers//AWCarbon CF F/R Spoilers-Side Splitters-Diffuser 6WB/ID6 HU+HUD/IND M4 Alcantara Armrest//PURE S2 Turbo//AA FMIC+DP//ER CP+TIC//3.5bar TMAP/TS DV//AWE Tuning Exh w/Blk Tips//Turner MS CF Intake//BM3 Cary Jordan Tune//MPerf Diff//PrecRW Ignition Kit
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09-02-2015, 08:15 PM	#10
chi2410 New Member 4 Rep 25 Posts Drives: BMW 330xi 2006 Join Date: Mar 2014 Location: meriden CT iTrader: (0)	helicoil is very easy to use, just read the instructions and in the future if you need to use it, then you know how, that way you don't have to pay to another person to do the job/ safe money. or check some videos in youtube / how to use helicoil that help a lot, good luck. Last edited by chi2410; 09-02-2015 at 08:20 PM.. Reason: understanding
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06-08-2020, 12:28 AM	#11
anujkch@gmail.com Registered 0 Rep 2 Posts Drives: BMW 328i Join Date: Jun 2020 Location: USA iTrader: (0)	Question on Helicoil I am having the same issue where the threads in alternator are broken and I plan to go the Helicoil route. But my question is which helicoil kit do I need to go for? As there are multiple sizes. Also, what is the bolt size i.e. is it 10x1.5 or 10x1.25 , 8x1.25 etc. I want to learn what is the exact size of bolt and what helicoil should I buy and use? Also what should be the length of thread insert. Is it 40 or 10 will do. Does it have to be Aluminium coil? Last edited by anujkch@gmail.com; 06-08-2020 at 01:16 AM..
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12-18-2022, 08:29 PM	#14
Osdp1621 Registered 0 Rep 1 Posts Drives: Bmw 335i Join Date: Nov 2022 Location: Georgia iTrader: (0)	Did the JB weld work on taking the pulley out I’m having a similar problem of a stripped bolt on my idler pulley
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12-18-2022, 10:15 PM	#15
Bmw1939 Lieutenant 268 Rep 463 Posts Drives: BMW 2011 328i, 2008 BMW X3 Join Date: Dec 2020 Location: CA iTrader: (0)	Helicoil is your friend.
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