Sheared Bolt - Timing Chain Tensioner. Now what?

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by HendersonvilleDad, Jun 19, 2025.

  1. HendersonvilleDad

    HendersonvilleDad New Member

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    So, I just finished getting everything back together after a head gasket replacement. Took my time, worked very methodically, but something felt off when I was tightening the nut on the bottom of the timing chain tensioner - it started spinning and I thought I might have stripped the bolt. (I was using a torque wrench and the top one went on just fine, so I'm not sure what happened.)

    I figured I'd wait and see after finishing the job. Sure enough, start it up and it's dripping oil from the tensioner at a pretty good rate. I was thinking about putting a second nut on the end of it to tighten down, but I decided to check the existing nut and see what happened.

    Well, it sheared off. See photos.

    To my recollection, these threads are just part of the timing cover itself. Does anyone know whether it's possible to replace the bolts themselves, or does this require replacing the entire cover?
    IMG_9544.JPG IMG_9545.JPG
     
  2. Tombukt2

    Tombukt2 Senior Member

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    If really lucky and could get a small slip joint thin jaw pliers after some kroil soaked into threads and clean off stud sticking up. You'd be very lucky . Usually replacement is a thing or removal to get stud out.
     
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  3. Mendel Leisk

    Mendel Leisk Senior Member

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    What torque value, spec is 9 lb/ft.

    looks like if you remove tensioner you’ll have a decent amount of the snapped off stud protruding, enough to grip by some method.
     

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  4. HendersonvilleDad

    HendersonvilleDad New Member

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    Just to wrap this up:
    After removing the tensioner, I was able to remove the stud using locking pliers. For anyone who needs to do something similar, the replacement part number is 92132-80616. These are the two bolt studs that go from the timing cover through the tensioner.

    After getting the new stud in finger-tight, I put the nut on the stud and used it to tighten it just a bit further. I then reset the tensioner and reinstalled it to 108 inch/lbs with a more appropriate torque wrench (previously I'd been using one where that was about as low a setting as it would go, and I likely missed it when it clicked).

    Still getting some seepage from the tensioner (after tightening it up the first time, do I need to replace the otherwise-new gasket?). Since it seems to take several minutes to form a droplet, I'm likely to let it go for the moment.
     

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  5. Mendel Leisk

    Mendel Leisk Senior Member

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    Remove and reinstall, and lightly butter the gasket with form-in-place gasket? Assuming the drip persists.
     

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