1994 2WD, 4.0L
I was replacing my idler pulley and that female bolt thread on the mount is semi stripped. The threads sort of tighten up. I'm guessing worn from previous owner or dumb-as$ me did it.
I need to replace that mount. Be going to the yard next weekend if I can. I'm guessing it's a 3/8-16 bolt hole. Dealer tells me that old and idler pulley are discontinued.
I have a grade 8 bolt. Plan to cut off the hex and epoxy it in . If it fits. Then bolt the idler with a cinch nut.
Kicker is the new idler didn't fit Napa, too narrow mounting , bolt too long. And weird, the inner bolt washer rides on the inner diameter of the bearing. The original one I put back on rides on the outer diameter. Anyone know that bolt? I'm hoping I have the right one because I don't think it has much more 'unbolting' life in that female thread. To get home to be sure doesn't come out, I wrapped one turn of aluminum foil on it. And drove 60 miles home from work. Stopped every 10 miles and checked. It was 3am doing this.
Other suggestions?

 

any chance of a photo for clarification?

 

I watched a video for a Jeep Idler replacement. His had a screw on dust cover. Looked like a tabbed washer that screwed on the back. Mine did not have it. Is it supposed to? Can I get a hardened washer to use. And how thick? Guessing its 1/8" , 3/32"?

Inner Dust washer, Looks like a flat washer with tabs to screw onto the bolt


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Below is a picture from AZ similar to the pulley I bought from Napa. It has the small bolt insert that contacts the inner diameter Race of the bearing. Not the outer race support like I have. My bolt doesn't fit into the pulley due to the design

New Pulley, smaller Inner Race Support



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This is a picture from the video of the bolt with larger OD support attached to it like I have.

Larger Outer Race Support on Bolt
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Video I used for ref:
https://www.youtube.com/watch?v=axAltpW8wR4#t=49.35229
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I just checked the Napa site. I think he gave me the wrong pulley! Oh man.

Gave me #1. I have #2 with the wider inner part for my bolt.

 

The dealer lists the wrong part for this bolt. But I'll give kudos to Jack Powell Jeep in Escondido for their help. Mechanic Bill went out of his way to help find what the heck it is. Best we came up with is that its a 10mm-1.50 bolt. With that I can work a solution to bolt the pulley in until I replace that mounting bracket.
I now have the correct idler pulley. Went back to Napa and exchanged. Now I'll replace it and try threadlock on it. If it is not working, I'll JB Weld it in and then get the bracket next weekend.
On another thread, guy said that 1994 does not have an inner dust cover washer.
Any suggestions are appreciated.