Tensioner Pulley Seized to Alternator Bracket

taylormade73

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Anyone ever dealt with the tensioner fusing to the bracket? When changing my PSP, I checked all the other pulleys. All were fine but the tensioner which had some play. I had an extra, so I thought I’d better replace it now.

Took the bolt out and it wouldn’t budge. Started wiggling a flat edge in between the tensioner and the bracket to try to loosen it up. Still wouldn’t come off, so I applied a little more pressure and the tensioner came off, but larger alignment nub stayed inside the guide hole in the bracket.

Tried every thing I could think of to remove/dislodge it, but it seemed to be one with the bracket. Several hours later wrangling a right angle drill at every angle imaginable except the one I needed (head on), I finally got it drilled out. Sure did give me the fits. Had the PSP replaced and bled in 30-45 min, tensioner 2 hours.

While your in there…

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