sheared bolt in the drive clutch
 

all the talk about machining clutches had me itching to get mine done. i talked to some people about making a puller and went ahead and did that. it was made from a 7/16" fine thread bolt drilled out with a punch in the hole that would fit all the way in. i tightened it down and then couldnt hold the clutch and turn the wrench. i tried an impact wrench and it would go to a point and not any further. i decided it was not worth breaking it so i would just remove my puller and leave it. as it started coming out it got hung. all of the sudden the bolt broke and now i have a big problem and need some help. can anyone tell me the best way to remove this bolt that is going to be ridiculously tight? i bought a exctractor and tried to drill out the hole but it just screwed up the drill bit. any help would be greatly appreciated. it is an 02 club car. thanks

Re: sheared bolt in the drive clutch
 

i hate to say this but at this point if the clutch is still on i think the 1st thing to do is yank the engine out so you can work on it with some room.........if the broken bolt is in that tight thats what i would do.......wouldn,t want to but it can get very frustrating...................................8)

Re: sheared bolt in the drive clutch
 

If the bolt is broken off flush you can try welding a nut on the stub and trying to spin it out.

If thats not an option then I would load the cart on a trailer and take it to a machine shop. Have them take a look at it to see if they can get the bolt out. Hopefully it can be done with the engine still in the cart.

Tom

Re: sheared bolt in the drive clutch
 

that would be idea i was just thinking of the room you don,t have there in case you have to weld a nut on the end or something else drastic, i know its a few more hours work but with the clutch still on your just so limited on what tools you can and can not use.................................8)

Re: sheared bolt in the drive clutch
 

well i figured i would give you guys the update. a carbide tip drill bit ate away at the punch for a while then i used a rotary tool with a round grooved bit. about three hours and some back pain later i got the punch out. i did screw up the beginning threads so i will have to drill and retap. i appreciate the help. i was beginning to wonder if it would ever come out. when i finally got it out i threw that sucker across the shop.

Re: sheared bolt in the drive clutch
 

The clutch itself can be retapped , I had one on an ezgo that had 1" threads in the clutch , so the threads in the clutch tho important they can be replaced , spray it down good with a good penetrating oil , and
get a bigger eze out . I would stay away from a torch as you may mess up the seal on tha shaft behind the clutch .

Re: sheared bolt in the drive clutch
 

oh i forgot to mention i got the bolt out as well. just wondering if i should use fine thread again when i retap as it was a 7/16 fine thread to start with. i know i have a 1/2 fine thread at work.

Re: sheared bolt in the drive clutch
 

as long as it will tighten back up i would stay with what came out unless your forced to go another way..........good deal on getting it out i have a bad back so theres no way i could have put 3 hours into bending over like that......for me it would be easier to have yanked the engine and put it on a bench............glad to hear it worked out.....................................8)