Tensioner Problem After My Build..

[RayfieldsWRX]

So my car runs great...but I ran into a little issue today. Picked up the kids from my wife in my WRX, and started for home, when suddenly a very loud screeching sound started coming from the engine bay. It seemed to be tied to steering action, so my first thought was either the belt or my power steering pump. I got it home (with it screaming intermittently), removed the pulley cover, and saw that my V-belt for my PS unit and alternator was VERY loose. Upon closer inspection, the lock bolt was completely loose.

At first, I was happy about it; simple fix, adjust tension and tighten lock bolt, done...but unfortunately it appears that the lock bolt has been badly cross-threaded at some point during my engine's re-assembly. The threads in the alternator seem to be pretty much gone.

I've rigged it for the time being with a piece of hardware I had around the house. Basically it's a slightly smaller bolt with a nut behind the alternator that's holding the lock in place so I can tension the belt...but it needs a proper fix. What's my best option to do this? Remove the alternator and have it tapped for a larger size? Or is there another accepted way to fix this? Obviously I'd rather not spring for a new alternator if I can get away with it. My build has pretty much broken my car budget for a while.

Thanks for any input!

edit: I do realize that I need to bring this up with the shop that did my work. I will do so on Monday, and perhaps they can help me out as well.

[SD_GR]

I have done both solutions on different cars -- I've used a longer, thinner bolt with a nut holding it where it "exits" the alternator, and I've re-tapped and re-threaded the alternator itself. The latter seems the more elegant solution but I suppose either will work. I'd feel better if the nut holding the bolt is unable to back out physically, so that means either a wire to hold it, a double nut, or a "locking" type (nylon ringed) nut.

[RayfieldsWRX]

A locknut did cross my mind..I can keep a few around for future tensioning adjustments.
I have access to a fair variety of hardware at the shop at my work. I'll take a look around on Monday and see if they have something I can use. Thanks, DanAlSpiro!

[06wrx4me]

couple choices:
new alternator
helicoil
long bolt nut through back
drill and tap


I like heli coil or drill and tap

[RayfieldsWRX]

Heli coil is an interesting option.

[SD_GR]

If you don't have that size laying around though a coil set will cost more money than simply tapping, it's up to you. A coil is a more "attractive" option since theoretically that bolt will have the strongest threads in the entire engine (some expen$ive all-Al motors come with steel thread inserts for their bolts, ours do not