Alternator Bolt stuck

Dealing with a rounded-off bolt that's stuck due to oxidation can be frustrating. Here are some steps you can try to remove the stuck bolt:

Soak the Bolt: Apply a penetrating oil or rust penetrant to the area around the bolt and let it sit for several hours or overnight. This will help to loosen the rust and make it easier to remove the bolt.

Use a Bolt Extractor: Bolt extractors are specifically designed to remove stripped or rounded-off bolts. These tools grip onto the bolt and allow you to turn it counterclockwise to remove it. Be sure to use the correct size extractor for your bolt.

Heat the Bolt: If you have access to a heat source, carefully apply heat to the area around the bolt. The expansion and contraction caused by the heat can help break the bond between the bolt and the sleeve. Be cautious not to overheat surrounding components.

Use a Chisel or Punch: If the bolt is accessible from the backside, you can try using a chisel or punch to tap on the bolt head while turning it counterclockwise. This can help to break the rust bond and allow the bolt to turn.

Weld a Nut: If there is enough space around the bolt, you can try welding a nut onto the rounded-off bolt head. Once the nut is securely welded, you can use a wrench to turn the nut and remove the bolt.

Cut the Bolt: If all else fails, you may need to cut the bolt using a cutting tool like a hacksaw or a rotary tool with a cutting wheel. This will allow you to remove the bracket and then address the remaining bolt separately.