Hardware for Alternator & Belt Tensioner


yummycurryboy

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Nov 9, 2019
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55
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Greater Philadelphia
Hey everybody,

I posted about a month ago about the bolts in my alternator bracket being seized up. Of the two bolts holding the alternator to the bracket, I only got one out. The head came off of the other one and is still stuck in the bracket. One of you generous members had the graciousness to send me a replacement alternator bracket!

Anyway, I want to replace the two bolts that hold the alternator to the bracket and the torx screw that holds the belt tensioner to the alternator bracket. I have a brand new tensioner that I will be installing.

Does anybody have any tips on acquiring these three pieces of hardware?

Any advice is appreciated! This is for my 2000 Sahara with a 4.0.
 

97' 4 Popper

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Oct 11, 2020
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CNY
So I noticed you've made a few posts about this and they weren't answered immediately. That's okay it's weekday night.

I tried doing some quick research and couldn't find too much on what size they are. May need to look deeper. I did find on quadratec a tensioner that comes with the bolt. Obviously that doesn't help you if you already have the tensioner. Since you got one of the bolts out your best bet is to go to a local hardware store and have them measure the thread diameter, pitch, and length if you don't have a thread gauge.

Also you say the torx bolt is seized but you didn't snap the head yet? Spray with kroil for a week multiple times day and try to remove. Liquid wrench is just okay, second to kroil for sure. If you haven't actually broken it yet have hope. I was able to remove the pinion nut on a 06' with 104k miles just spraying kroil every day, like every 5 hours, for one week. It came right out with an impact gun. I'm not an expert by any means but if spraying kroil removed a pinion nut it will help you with this smaller t40. It's either gonna break or break free, if you know what I'm saying.

I haven't actually done this job before, but someone in your other thread made the suggestion of going with bolt and nut combo instead of fully threaded, that might be ideal for easier later removal.

I'm also a "curryboy" btw lol. Good luck on finding the hardware. One of my least favorite aspect of things.
 
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qslim

The Man with the Big Yellow Car
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Utah
Hey everybody,

I posted about a month ago about the bolts in my alternator bracket being seized up. Of the two bolts holding the alternator to the bracket, I only got one out. The head came off of the other one and is still stuck in the bracket. One of you generous members had the graciousness to send me a replacement alternator bracket!

Anyway, I want to replace the two bolts that hold the alternator to the bracket and the torx screw that holds the belt tensioner to the alternator bracket. I have a brand new tensioner that I will be installing.

Does anybody have any tips on acquiring these three pieces of hardware?

Any advice is appreciated! This is for my 2000 Sahara with a 4.0.
You should probably be able to find something at a hardware store, just match the threads. Do you have the bolts or part of the bolts for reference?
 

CharlesHS

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Mar 10, 2020
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2,371
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Jacksonville, FL, Quezon Philippines
Hey everybody,

I posted about a month ago about the bolts in my alternator bracket being seized up. Of the two bolts holding the alternator to the bracket, I only got one out. The head came off of the other one and is still stuck in the bracket. One of you generous members had the graciousness to send me a replacement alternator bracket!

Anyway, I want to replace the two bolts that hold the alternator to the bracket and the torx screw that holds the belt tensioner to the alternator bracket. I have a brand new tensioner that I will be installing.

Does anybody have any tips on acquiring these three pieces of hardware?

Any advice is appreciated! This is for my 2000 Sahara with a 4.0.
A great penetrant to use would be to mix a few ounces of Acetone to a few ounces of ATF; this mixture creeps into the rusted bolt threads. When PB Blaster, Kroil and Mouse Milk do not work.... this mixture can...
 
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OP
yummycurryboy

yummycurryboy

Member
Joined
Nov 9, 2019
Messages
55
Location
Greater Philadelphia
So I noticed you've made a few posts about this and they weren't answered immediately. That's okay it's weekday night.

I tried doing some quick research and couldn't find too much on what size they are. May need to look deeper. I did find on quadratec a tensioner that comes with the bolt. Obviously that doesn't help you if you already have the tensioner. Since you got one of the bolts out your best bet is to go to a local hardware store and have them measure the thread diameter, pitch, and length if you don't have a thread gauge.

Also you say the torx bolt is seized but you didn't snap the head yet? Spray with kroil for a week multiple times day and try to remove. Liquid wrench is just okay, second to kroil for sure. If you haven't actually broken it yet have hope. I was able to remove the pinion nut on a 06' with 104k miles just spraying kroil every day, like every 5 hours, for one week. It came right out with an impact gun. I'm not an expert by any means but if spraying kroil removed a pinion nut it will help you with this smaller t40. It's either gonna break or break free, if you know what I'm saying.

I haven't actually done this job before, but someone in your other thread made the suggestion of going with bolt and nut combo instead of fully threaded, that might be ideal for easier later removal.

I'm also a "curryboy" btw lol. Good luck on finding the hardware. One of my least favorite aspect of things.
Hell yea curry boys! Love it! I'll try to keep soaking this T40 and see if it comes out. At this point I would gladly pay $50 for a new one though. Jeep has been sitting for 2 months now and the weather is excellent.

Not too worried about the alternator bolts. The one I have doesn't look too bad and the other should be easy to match.
 

97' 4 Popper

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Oct 11, 2020
Messages
132
Location
CNY

If quadratec confirms that this comes with the bolt, I might just order it. I guess I did say I would pay $50...

I would try and get the bolt out atleast first so you can measure it, and maybe if t40 head bothers you can replace it with something less likely to strip like a normal hex head.

He is yummy in my book for sure!

200.gif
 

Bumble Beep

Member
Joined
Aug 26, 2019
Messages
53
Location
Chicago
I just did this...
- Tensioner: Mopar part 4854089AB. From Amazon as CharlesHS suggests, comes with the torx head bolt. I don't think it would be a good idea to substitute this bolt, as the head seems to have a taper for positioning/securing the unit.
- Idler pulley: Mopar part 4854092. Also on Amazon, also came with bolt.
- Serpentine belt: Mopar part 4854033AB. Again on Amazon. For a 4.0 L with AC, so may be different for others.
- Figured the alternator would eventually die, so might as well free up the bolts before they get too settled in. Lower bolt came easy with an impact wrench, but the upper bolt could not be accessed with the impact and felt "springy" with breaker (didn't want to shear off). Had to remove the 4 bracket bolts and alternator wires first, removed the alternator/bracket, then heated the upper bolt with a propane torch for 5 min and attacked with the impact. It came free, with some aluminum in the threads, but scratched them out with a blade and the bolt went back in without issue. Use some anti-seize on the treads and install bolts with the recommended torque x 0.8. Good luck.
 
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yummycurryboy

yummycurryboy

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Joined
Nov 9, 2019
Messages
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Location
Greater Philadelphia
I ordered the Mopar tensioner! Tired of dealing with this headache. Fingers crossed that this is the last piece of the puzzle. Although I still am not 100% sure the alternator was the problem to begin with.

Side note, if anybody is interested I have an alternator bracket with a broken bolt stuck in it and tensioner attached (although the screw is seized). I also have a brand new Gates tensioner without the screw. Up for grabs.
 
OP
yummycurryboy

yummycurryboy

Member
Joined
Nov 9, 2019
Messages
55
Location
Greater Philadelphia
I just did this...
- Tensioner: Mopar part 4854089AB. From Amazon as CharlesHS suggests, comes with the torx head bolt. I don't think it would be a good idea to substitute this bolt, as the head seems to have a taper for positioning/securing the unit.
- Idler pulley: Mopar part 4854092. Also on Amazon, also came with bolt.
- Serpentine belt: Mopar part 4854033AB. Again on Amazon. For a 4.0 L with AC, so may be different for others.
- Figured the alternator would eventually die, so might as well free up the bolts before they get too settled in. Lower bolt came easy with an impact wrench, but the upper bolt could not be accessed with the impact and felt "springy" with breaker (didn't want to shear off). Had to remove the 4 bracket bolts and alternator wires first, removed the alternator/bracket, then heated the upper bolt with a propane torch for 5 min and attacked with the impact. It came free, with some aluminum in the threads, but scratched them out with a blade and the bolt went back in without issue. Use some anti-seize on the treads and install bolts with the recommended torque x 0.8. Good luck.
Definitely using anti seize! Yea, I ended up shearing the upper bolt head right off.