So I had both my bolts break over time and decided to get a new alternator and bolts.....I decided to buy a similar but not exact pair of bolts(45mm vs 50mm).

Bottom bolt doesn't hold much of a grip and the top one needed to be torqued like crazy before finally cracking off the head so now I have to use an in-out with a drill to get the left over screw.

Most guides on putting in this alternator didn't bring up needing the unusual bolt from Honda as a requirement or did I just torque it like a moron?

 

Did you use a torque wrench ?, sounds like the threads have been abused in the past from over-torqueing.

 

Yeah, I had to use a torque wrench...tight as a mofo at top...was able to use my hand at the bottom.

 

The threads are either stripped or the bolt is too short on the bottom ? The bottom bolt needs to be 95mm long.

 

Sounds like you used a bolt with the incorrect pitch on the top? Or else someone had previously cross threaded that bolt hole and nackered the threads.

The top should be M10x45 and the bottom should be M10x95. I'm not sure what's "special" about the upper bolt according to Honda.

If you tightened that top bolt so much that you snapped the head on an M10 bolt, then you ain't getting that thing out with any kind of drill extractor kit. Be prepared to drill that bolt out. Gonna be a pain.

 

Bottom is 95?

That would have helped to know.

Figure I'll have to use a drill and blow torch.

 

Do not use a blow torch. Take it to someone who actually knows what they're doing. Not sure how one would repeatedly brake bolts that big. I suspect either the wrong thread pitch was being used or the threads in the brackets were stripped. The brackets are soft aluminum and heating them with a torch can cause severe damage to not only them, but also all the sensitive components around the mounts. (O-rings, electronics, hoses, etc)

 

I wonder if that's why the first bolts broke in the first place....alternator was hanging by a thread and sent the original belts flying one day.

Damn, suppose I could drive it to a shop but without a belt I risk overheating...there is one a mile away

Alternatively I could hire a craigslist mechanic for $60-100+ to get it out.

Any ideas on how I should procees?

 

I just checked online....turns out the alternator bracket is replaceable...$70 bucks online!

Best option? Especially since the threads might be borked?

 

You can drive a mile without overheating as the thermostat won't even be open by that distance. Paying for a thread repair may be as much as a new bracket, if you get the bracket get the new bolts to go with it.