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Discussion Starter #1
Hi guys,

I hope everyone is well,

I have just purchased my first Alfa, its a 147 1.6 TS, I got it cheap as it has a clunking/knocking sound when driving, today I've had it up in the air to try to diagnose the problem.

What I've found is that there is a broken bolt on the gearbox where the support mount is located near the exhaust flexi joint I have attached an image showing this, any advice on the easiest way to remove the broken bolt so I can put a new one in?

Additionally to this another problem is that there appears to be some kind of torsion bar support that mounts from below the starter motor down to the same mount area that the bolt has broken, this bar appears to have been welded at some point and appears to be too long and pushing the bracket down too low so it doesn't line up, does anyone know if this bar looks correct? Is the length of it normally fixed or adjustable? I think its probably better to replace it so does anyone know where I can get one from?

Apologies for all the questions but I really want to get this lovely car sorted so I can start driving it :thumbup:

Thanks in advance for any answers or advice :thumbup:

Geoff.
 

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I'd be lying if I told you there was an easy answer.......The only way I can see is to remove the mounting completely and see if you have room to get a right-angle drill in to get a pilot drill into the sheared bolt, then try a good quality reverse tap ("Easy out"). Failing that its probably a case of gettting the engine and box out to get at it properly.

Can't really see what you mean by the torsion bar - there is a 7 - 8" steady bar which goes from the block to the rear engine mount - tubular but with a flat flange at both ends......
 

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Discussion Starter #3
I'd be lying if I told you there was an easy answer.......The only way I can see is to remove the mounting completely and see if you have room to get a right-angle drill in to get a pilot drill into the sheared bolt, then try a good quality reverse tap ("Easy out"). Failing that its probably a case of gettting the engine and box out to get at it properly.

Can't really see what you mean by the torsion bar - there is a 7 - 8" steady bar which goes from the block to the rear engine mount - tubular but with a flat flange at both ends......
Hi mate,

Thanks very much for the reply,

Thanks for the advice with regards to removing the snapped bolt, with regards to the bar yeah I mean the steady bar (wasn't sure how much describe it), if you look at the photos it looks like its been welded near the hole were the bolt goes through at the top, I don't know if it's now the correct length, maybe this has contributed to the bolt snapping. As I stated in my previous post it appears to be pushing the mount down so the bracket hole/gearbox bolt don't line up, do you think it just needs twisting so it lines up or should I get a new steady bar?

After a bit of research it appears that other owners have had this bolt snap, does anyone know the reason why it snaps?

Any idea where I could obtain a new stay bar and a replacement bolt for the one that has snapped?

Thanks again for any replies/advice,
Geoff.
 

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Normally I would be able to supply you a steady bar - I've got a few kicking around, but I'm away on holiday tomorrow until after Xmas......(the perks of being more or less retired ;) ).

Now I've had chance to look at a larger image, the one in your pic doesn't look like a standard item - normally they are a black tubular effort with flattened flanges at each end - so maybe someone has cobbled something up......(I get a "404 not found" message when clicking the link above......)
 

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Is it Part #7 in the attached diagram/file? if so its part number 60625883.

As to the broken bolt, a drill and eazi-out is probably the best option if you can get access. You could try drilling out the hole to close to the thread size and re-tapping the thread but again it depends on how much access you can get!
 

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Broken bolt remover

Hi,
About the broken bolt, I know the tap remover machine could solve your question well. but to buy one set tap remover machine is not cost-effective for you. So you could ask someone who has the broken tap remover machine for help.
You could tell me your city address too, I will see if there is something I could do for you.

Amy
Skype:amynie2015
 

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Hi Geoff,
About the broken bolt, I see the size of it very large, the broken bolt remover machine must could solve your problem well. However it maybe not cost-effective to buy one set broken bolt remover machine for you, so you could ask somebody who has the edm for help. Or if you are willing to tell me your city, I will see if there is something I could do for you.

Amy
Skype:amynie2015
 

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Discussion Starter #9
Hi guys,

Thanks for the replies,

I am going to have a go at drilling out the bolt and re-tapping or using an "easy out", to gain access to the remainder of the bolt i will need to remove the support bracket that the bolt goes through.

Does anyone know if its going to cause a problem if i remove this bracket temporarily to gain access, the engine/gearbox assembly is not going to drop out is it? I assume it will be OK to be temporarily supported on the remaining mounts?

Thanks in advance,
Geoff.
 

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It won't fall out :) although it may tilt a bit - you can always support the engine with a jack with a piece of wood to spread the load onto the front of the sump.

I think you may find you've another snapped or missing bolt, as there should be one screwed into the side of the sump...if that was intact I don't think you'd have had as much movement as it appears you have.......Hope its loose or missing rather than broken.......
 

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Discussion Starter #11
It won't fall out :) although it may tilt a bit - you can always support the engine with a jack with a piece of wood to spread the load onto the front of the sump.

I think you may find you've another snapped or missing bolt, as there should be one screwed into the side of the sump...if that was intact I don't think you'd have had as much movement as it appears you have.......Hope its loose or missing rather than broken.......
Hi mate,

Thanks for the reply,

Not sure which bolt you mean that goes into the side of the sump, could you possibly point out which one you mean in one of the images i originally attached?

Cheers,
Geoff.
 

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Number 9 in post #6 above......
 
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