G14 Secondary clutch blew apart (i think)

[chubzilla]

Tearing down my '96 G14 for some maint. before spring. Noticed the secondary clutch bushing was wore, so decided to remove it so I could change out the bushing and install a new torque spring.
Here's where it took a turn for the worse. The nut holding the clutch on was completely rounded off, so I bought a nut splitter. Split the nut with no problem, but when the nut split, it disappeared somewhere in the garage, and the whole clutch assembly shot off the shaft smashing my arm against inside of the frame. It gets better, the reason the nut was rounded is because it was either the wrong thread or was cross threaded and installed with an impact. I have no threads left on the end of the input shaft.
My plan is to try and run a die over the end of the shaft. Now the threads are gone the diameter is checking about 7/16, so it will be a standard nut and not a metric (no big deal since I'm doing the wrenching). Not sure how well its gonna work but I sure as hell don't want to replace that shaft.
As Far as the secondary clutch goes, I have watched the Jakes power spring install video on youtube. It looks pretty straight forward. Then I read some threads on here and they talk about preloading the clutch, picking holes for the spring (B3 and B4). So I'm confused at this point.
Do I assemble the clutch on the bench and preload? if so is there a video or link to show and explain that process?
I picked this cart up for about $1200. It runs great except for the worn out bushings in the clutch. I thought I was getting a smokin' deal. Now I'm starting to wonder. Please any and all help will be appreciated.
Thanks ahead of time

[craig tn]

The jakes power spring does not have to be spring preloaded. Only the factory springs gave to be preloaded since they have tabs to go into the b3/b4 holes on the clutch and spring seat. The clutch will have to be assembled on the shaft. If you use jakes follow there video.

[BamaG14]

Chub I got a 96 g14 also and replaced my secondary spring twice. First time ordered jakes spring not knowing it had already been replaced with one. So I got two springs with splined washers now. I ordered Plowmans performance kit after talking to him. The kit come with complete clutch ,a spring he recommended for my usage,his muffler,and larger jets for carb.

It's not quite as easy as it looks on Youtube unless you got another pair of hands. I replaced mine the second time by myself using a rachet strap to pull the slider in to get washer and nut on. Spring is just to strong at least for me to push it in and screw nut on at the same time . That spring is under a load as you found out after cutting that nut.

Hope you can get shaft re-threaded.

[BamaG14]

Chub that's the fixed side not slider side I had to pull in. Just wrapped the strap around frame and outer and rachet in. Had to bump it by hand a little with it being new til it was on enough for washer and nut.

[chubzilla]

Thanks for the insight Craig and Bama!
If I can figure out how to upload pics I will start a build thread so everyone can see how bad I screw this up. lol
I have till April 18 to get it done. That's when the campground opens.

[chubzilla]

bump