To solve your problem you must read the repair manuals to fix the problem if you don't have manual i am sending you a link from you can get it easily http://toolsnyou.com/
SOURCE: Starter removal
believe it or not, your last statement is not untrue. I had a long talk with an engineer from ford some years back. You would not believe the amount of testing they do to make sure that parts DO NOT last beyond a specified lifespan. (you would think it would be the other way around!!!) About your problem...now you know the need for proper testing BEFORE making a repair decision. First thing you test is the battery (static charge and load test) when dealing with any electrical problem!!! Never assume anything is good till it tests good!
SOURCE: 1998 chrysler town & country 3.8l- how do i get
you dont have to take it off. remove the 2 15mm bolts and pry the bracket sideways w/ a prybar. This shortens your time. You most likely have a 90amp alternator so it should be small enough to slide through.
SOURCE: 1995 Ford Taurus V6-182 3.0L
If you can remove the bolt remnant without damaging the parent metal, you should be able to reinstall the tensioner. Get a new bolt directly from Ford so that you are sure you have the correct length, thread pitch, and hardness. If you are not very experienced in removing broken bolts, you may want to seek some help with this.
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