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Dexter J - 08 Apr 2005 20:42 GMT

Salutations:

So. I have a broken tensioner mounting plate on a 1993 Aero.

The tensioner, belt and pulleys are fine - but the whole unit came loose
and then snapped off the block (leaving at least two bolt halves to be dug
out).

Anyone else run into this before?

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yaofeng - 09 Apr 2005 10:32 GMT

Not personaly, but I did have the tensioner top bolt snapped off on two
of my 94 9k's on different occasions. Let's see, the bracket is
mounted on the timing cover by a countersunk screw (not unlike the ones
on the brake rotor) and another torx screw in addition to the long top
tensioner mounting bolt. Memory escapes me. I am not sure the long
top tensioner mounting bolt also fastens the bracket to the cover or is
there a third torx screw on the bracket.

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Dexter J - 10 Apr 2005 01:37 GMT

Salutations:

> Not personaly, but I did have the tensioner top bolt snapped off on two
> of my 94 9k's on different occasions. Let's see, the bracket is
[quoted text clipped - 3 lines]
> top tensioner mounting bolt also fastens the bracket to the cover or is
> there a third torx screw on the bracket.

Thx for the leads.

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Charles C. - 09 Apr 2005 12:05 GMT

> Salutations:
>
[quoted text clipped - 5 lines]
>
> Anyone else run into this before?

Not personally but SAAB knows about it ;-)

When I got the belt on my 9k (1997) replaced and I was asking questions
about the tensioner ... they were saying it does not fail often but
if/when it does it causes damage like you describe. It rips some plate
is what they told me.

Sounds to me (I have not seen how the componenets fit together) that the
pressure on the tensioner fatigues the bits it sits on.

Charles

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Dexter J - 10 Apr 2005 01:45 GMT

Salutations:

>> Salutations:
>> So. I have a broken tensioner mounting plate on a 1993 Aero.
[quoted text clipped - 14 lines]
>
> Charles

I'm going over the bolts now - it appears that the tensioner and pulleys
are fine. The plate and one (perhaps two if brother yaofeng is correct)
have sheared.

I'm wondering if a bolt worked loose on the upper section of the tensioner
- then caused a cascading failure through to the mount plate. The roads
around here are notoriously rough come the early spring and summer and
it's been taking a beating rolling around town.

I think I'll locktite the bolts this time round, but I have to admit to
being a bit surprised at having a part work loose down there. All part of
the exciting world of utility classics I suppose. Makes me worry a bunch
about what the previous owner had done in there.

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yaofeng - 10 Apr 2005 02:25 GMT

Indeed my memory failed me. See below,

http://www.imagestation.com/picture/sraid147/p5e5792d529d8a6f7aa2d2e1116a5bbcf/f
63ab7ad.jpg

This is a picture I took when I did a 94 9k cde auto to 5 speed
conversion last November. The tensioner top bolt is bolted onto the
timing cover. The bottom of the tensioner is attached to the bracket.
The bracket has a round pin where the tensioner bottom connection is
fastened by a circlip so it can rotate.

Now the bracket itself. You will note the bracket is triangular. It
is mounted onto the timing cover by three torx screws. One of the
three is countersunk. If memory serves (which it apparently didn't the
previous time) the three torx screws are to be tightened to 15 ft-lbs.
If only the bracket failed, I consider you lucky. It is much less
expensive than if the top tensioner bolt took out the mounting
attachment on the timing cover, in which case you'll have to replace
the timing cover.

BTW I don't think it is difficult to remove the broken bolt shank stuck
in the hole. Experience tells me the shank is loose in the hole. You
know the bolt tension is no longer there. So there is nothing much to
prevent the shank from being extracted. A pair of needle nose pliers
and patience will do.

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Dexter J - 11 Apr 2005 00:59 GMT

Salutations:

> Indeed my memory failed me. See below,
>
[quoted text clipped - 20 lines]
> prevent the shank from being extracted. A pair of needle nose pliers
> and patience will do.

Thank you again - the photo is actually very helpful and I've grabbed a
local copy.

Hey - you don't happen to have a green 9000 you are parting out do you?

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yaofeng - 12 Apr 2005 02:01 GMT

I am parting out my maroon 94 9kcs.

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