200Tdi Fan/Alternator Belt and Steering Pump Belt adjustment SNAG!!

On attempting to adjust both the fan drive belt and the power steering pump drive belt on my Defender 200TDi I find that some bright spark has rounded off the heads of all of the pivot bolts and adjustment bolts on both the alternator and the steering pump- all 10mm. The bolt on the alternator adjusting strap (13mm) has undone ok but even here I find that the original bolt has been replaced with a nut and bolt (he must have stripped the original) with no washers being used! I know that this must be a pretty bog-basic engineering dilemma but I am at a complete loss as to what to do next.

I managed to adjust the fan belt with a bit of gentle tapping on the alternator but I am now sweating on what happens when I have to change either or both belts – and that will not be long by the look of them!

Has anyone got any good ideas? Is there some sort of bolt extractor that I can buy that could get the job done? There is precious little room to get in and drill them out!!
:doh:

It might just help if you use hexagon socket if they not completly rounded, or how about sawing a slot on the head of each bolt and wack em with a inpact driver.

have a similar problem with my 200tdi disco engined 90
could probably get um out with a good strong pair of hands and a pair of mole grips , order some new 1's before you do so you can bin the fooked 1's

Smack a slightly smaller socket over them - be prepared to scrap the socket and the bolts though.

try imperial sockets they is slightly smaller

Angle Grinder, fits all size bolts! then replace with new m8 bolts, use std m8 bolts with 13mm hex head and washers.

if you, hit bolt head enough times and then hammer socket on they will come eventually ,weld nut on head ,snap on do sockets that are built for this ,just bought a set work perfect

get yerself some rounded nut removers.

small stilsons pipe wrench, better than mole grips cos the stilsons grip tighter the harder you pull

Thanks for all of the advice everyone. I have taken the fan shroud and fan off for better access and have ordered the two new belts. I have also ordered a set of Irwin Bolt Extractors from tools247 on amazon.co.uk. I've discovered that the likes of Paddock Spares don't carry general hardware like the mounting bolts and I need to find a motor factor round here - I am a bit out in the sticks- who can supply me with similar. Once I have the belts and some spare bolts handy, I will have a go at fitting them. I am a lot more confident now of getting the job done. Thanks again, I will report back on how I get on.

I bought that Irwin kit a couple of years back when my brake caliper bolts were rounded, these are almost always bihex headed bolts and using a standard hex will round these off, which looks exactly like that the last person who had them off had used.

Anyway, they are good to a point, I found that deforming the head even more helped the remover get a good bite. The bolt was VERY stuck in my case and I ended up welding a nut onto the stuck caliper bolt, the heat down the thread and the ability for me to horse it with a 2 foot breaker bar soon removed it!