So my alternator (I'm assuming) died on the interstate on me today. Got it towed home. Got the top t30 bolt out ok but the bottom t45 bolt isn't going so well. The t45 socket fits ok, but as soon as I start applying torque you can tell it's stripped. Looking at the end of the bolt it doesn't look great.

Any suggestions other than trying to take a dremel to it and slotting it? I heard there may be some type of "turbo" socket which might work?

Other question, where's a good place to buy a replacement bolt? I'd like to be able to go to a store and buy one, is that going to be possible?

 

Squirt PBlaster on the side of the bolt towards the head. Heat that area if you can do so safely without getting near the fuel lines. Put the largest, sharpest, newest Torx bit that will start into the bolt in place, and tap it with a hammer until it is fully seated. Tap it a few more times to shock the threads. Use a breaker bar off the Torx bit to where you can get at it, and strike it forcefully to the left. Use the palm of your hand or a mallet, but whack it, don't just push or pull harder and harder until the bolt strips.

When you put it back together, use anti-seize.

 

I'm not sure I have enough room in front of the bottom alternator bolt to really get a hammer on there.

To be clear, ti's the torx head on the bolt that is stripped, rounded, whatever you want to call it. I'll snap a pic.

 

 

I got it out! I remembered I had a set of Irwin bolt extractors and I was able to get one of them on the end of the bolt and it came right off.

Now I just need to find a replacement bolt at a store somewhere tomorrow.

 

...Or a stud and a nut (probably easier).

 

Sounds like you've got it under control.

What I was getting at is that different brands of Torx sockets and often different sizes will fit the bolts differently. The bolts are usually soft enough, that the largest size you can barely get started, can be tapped in with a hammer to fully seat the Torx bit and bite into the bolt. Even when the bolt is mangled, a fresh Torx bit hammered in, can reform the "teeth" and cut into the bolt enough to back the bolt out. Some brands are far enough out of spec (think Made in Taiwan crap in the hardware store discount bin) they're loose in the bolts, or they don't fit at all. As they wear, even the good Torx bits lose some of their tooth, making them more likely to slip and strip the bolts.

Sometimes it's handy to keep Lisle, Craftsman, and other name brand Torx bits on hand, so you can try different bits for the best fit.

 

Got it, thanks for the advice!