The nut under the alternator that needs to be loosened to release tension on the belt is frozen, rusted, and rounded off. So I cannot get the alternator to move in order to get the belt off.

Any suggestions?

 

I would hold off changing the belt.

I loosened the through bolt, then the adjustment lock nut. Then I loosen that tension bolt. Did you loosen the adjustment locknut or the through bolt? See attached pic.

 

After struggling with the "adjustment locknut" for awhile and getting nowhere due to it being rusted/rounded, I did take out the "through bolt" and loosened the "adjusting bolt" (the one pointing to the front of the car), and I attempted to push the alternator forward and down where the through bolt was (using a hammer and pry bar), but it was pretty stuck in place. I was lucky to get the hole realigned to put the through bolt back, well, through...

The adjustment locknut is in such an awkward place I'm not sure how I can even access it. Usually in these situations I try to clamp vise grip pliers onto the rounded nut and work it that way - but there is no room for me to do that here...

The PS belt came off easily enough - but so annoying to not be able to change the other belt.

 

I thought the 10mm bolt was rounded, not the 12mm nut. I just used a deep 12mm socket on that nut to loosen it.

Now that it is rounded off, you may want to try hammering an 11mm socket on it. There are special sockets you can get at a parts store that have grooves in them to grip a rounded bolt head that may work.

I think if you remove the whole 10mm adjusting bolt on the bottom, then that adjustment bolt with messed up nut should be able to be pushed out (towards the driver's tire. Then the alternator should be able to rotate.

 

The accessory belt is "in the way" of access to the lock nut that is rounded. You can cut the belt for bettter access. However, this commits you to repair the lock nut to reinstall new belt.

Rounded nut/bolt socket as PAH suggests is way to go, but you may need to cut the belt for access.

good luck

 

Thanks for the suggestions! I don't really see how there is any room to hammer an 11mm socket on- I did try to push one on but it wouldn't go.

I will try to completely remove the 10mm bottom adjusting bolt and see if it moves. I had considered cutting the belt for better access - but I wasn't quite ready for the commitment, lol!

I agree - I will have to scope out some of those special sockets made for rounded bolts - that may be my best bet. Thanks!

It's ironic - I was working on replacing the left cv axle and wheel bearing at the same time - THAT went without a hitch, but a simple 10 minute belt change ends up causing me all this grief...

 

I found w/ belt in place I could only reach the nut w/ a 1/4" ratchet, 3/8x1/4 adapter and 3/8" drive, 12mmsocket. This was long enough to reach the nut but short enough to fit in available space w/ accessory belt in place. Even so it was tricky. You may need this arrangement w/ the rounded nut socket (Craftsman has them).

good luck

 

I was able to get in there with a 3/8 ratchet, shortest 3/8 extension and deep 12mm socket. Awkward, but I needed the 3/8 ratchet for the extra leverage (not that it helped...). I even tried it from below since I had the wheel and axle off, along with the knuckle pushed aside, but it wasn't any better access. Sprayed it with lubricant and even hit it from underneath with a MAPP torch to no avail. I didn't spend a whole lot of time with the torch because I was afraid of something getting too hot inside the alternator.

 

So did it move, doesn't sound like it, or did the nut strip?

More leverage.....got a piece of pipe

Edit: sometimes I'll give "it" a slight "rocking" in the other direction.

 

The nut was already rusted and rounded to begin with, so unfortunately all that moved was the socket, thus rounding the nut even more... If I can get a good grip on it with one of those Grip-Tite or Gator Grip sockets, maybe it will budge. I'll try to pick one up today.