repair after twisting off a bolt

Dan-IA · Dec 28, 2013

This is a forum filled with great minds and lots
of experience. I have a problem and don"t know
what the quick fix is while I wait for parts.

I have been working on a charging problem in a
car. Well it looks like the powertrain module in
my 1994 plymouth sundance behaves as a regulator
for the alternator, but it"s spendy so replacing
that is the last resort, I want to rule out
everything else first.

While cleaning the terminals and replacing the
wires, I snapped one of the tiny bolts that supply
a connection to the alternator for the stator
windings. The harness seems to hold the terminal
near the screw, but clearly it wont guarantee a
connection.

It"ll be a few days before I can get a replacement
alternator, but in the meantime, how would you
connect the wire to what remains of the terminal?
Thanks for the advice!

Dan

teddy52food · Dec 28, 2013

Clean it good & solder a wire on.

samn40 · Dec 28, 2013

Either, solder on a male spade terminal to the broken bolt and fit a female terminal to the wire... or, if the bolt is big enough then drill a small hole into it and use a self tapping screw through the ring terminal that is already on the wire.
Sam

Anonymous-0 · Dec 28, 2013

Clean it good & solder a wire on X2

Steve@Advance · Dec 28, 2013

Something you might try is opening up the case and see what's on the inside. I can't guarantee what you'll find, but typically they use a square headed bolt through a plastic insulator. Might be able to substitute a screw or carriage bolt with a little grinding on the head...

But before going to that much trouble, unless you have reason to believe otherwise, most likely the alternator is bad. PCM failure is rare in that area.

Did you check for battery voltage at the output terminal? This is typically a protected circuit with a heavy fuse or fuse link, sometimes this wire goes directly to the battery, check for corrosion at the battery terminal.

Hope this helps.

Sprint 6 · Dec 28, 2013

Alternator rebuild places can supply you a little regulator that bolts on those two terminals and eliminates the power control module from the charging circuit. I used to put tons of them on 18 years ago, don't know if they are still available or how much.

Sprint 6 · Dec 28, 2013

I will also add that the charging control circuit failure was very common in those power control modules. I made quite a living off of K cars. Timing belts, transmissions, head gaskets, ah the memories.

T in NE · Dec 28, 2013

If the PCM is bad you could also stick an old-style regulator in it, pretty simple.
Does your A/C work? A bad crank sensor could cause it to not charge, because it doesn't realize that the engine, yes, is actually running.

Super-H-Mike · Dec 29, 2013

Yes , me too ! I just had to do a timing belt on an 87 2.2, and it was kinda fun reliving all the memories ! lol I used to be able to do one in under an hour start to finish. As to the original poster, those old PCMs do control regulator and they did fail at times. We always wired in an old style firewall mounted regulator if the customer didnt want to buy a new PCM.

repair after twisting off a bolt

Dan-IA

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teddy52food

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samn40

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Anonymous-0

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Steve@Advance

Well-known Member

Sprint 6

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Sprint 6

Well-known Member

T in NE

Well-known Member

Super-H-Mike

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