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I have a ZD30 that has been shearing the bolt on top of the fan belt tensioner. This has happened twice now. I replaced the tensioner 10000km ago and it seams to be running freely when it is pulled off. the air con and alternator both run freely. It has been snapping after a few days of fixing so it seams that something is ceasing up after some time. Please help
I brought the tensioner / pully from Barnsons Auto. the first time it broke it snapped some of the casing, i had to heli coil a new thread deeper for the second one. i used a 4.6 grade bolt the second time but it sheared it so it seams to be a sudden force that it snapping it
now that section has snapped off, the new tensioner wont be sitting level and would have caused the bolt to snap no doubt in my mind. i would file it flat and pack out the gap difference with a washer or two.
i have the piece that snapped off and used it as a spacer, not shown in the photo sorry. the strange thing is it was fine for 4 days after i fixed it then just suddenly snapped again. Could it be the fan or alternator clutches? it seems like something is locking up
Use a genuine tensioner. My guess is the aftermarket tensioner is not giving enough rebound I suppose you call it, putting extra stress on that mounting point.
A failure on a factory fixture where there are many units out there suggests you are not at root cause. tapping the bolt deeper won't reduce the incidence of shear. Increasing the bolt dia will reduce the incidence of shear due to larger section, however the point remains that a larger load is being generated. Was the part that broke off fractured to begin with? Is the engine running differently under any circumstances - a/c on, first start up, hot?
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