1990’s Hyundai secondary clutch removal

[Vicamen]

Hello, All. This is my 2nd post on this forum. I have a 1990’s Hyundai golf cart. I am repowering it. I do not have the original drive clutch; only the driven clutch. Removing said clutch has been difficult. I removed the axle. The initial bolt came off easy. The large 2 1/8” threaded nut was more difficult but we persevered and it came off. The first sheave then unscrewed with more muscle applied to it. The spring and most of the clutch then popped off...with the exception of the shiny cylinder that covers the shaft and a little part of the housing for the spring. I’m not sure of the names of the parts. There is absolutely no access to the woodruff key plus I don’t know if this is threaded. Using a puller did nothing. I was told to heat which I will do next. There is obviously something I’m missing. I destroyed the clutch by just trying to remove it. Any thoughts how to get the remaining piece off?

[Vicamen]

Going to use the torch and see if heating it up will help it come off. If that doesn’t work I will use a cutting disc and carefully cut the stainless sleeve off; hopefully, I will not touch the shaft.

The plan is to continue to strip the cart of its body so that only the chassis and suspension remains. I will then sandblast it. I have two atv’s that I will strip of their suspension and front end and weld onto the cart. Paint the modified chassis and suspension. Fabricate a new cowl using atv and cart cowls. Install new 18 hp engine and new primary and secondary clutches. Hook up everything so it can be operated from the drivers seat and do final body painting.

This is gonna take a while.

[mikeasis]

I thought the Hyundai's used the Yamaha drive line but I could be wrong

[Vicamen]

Desperate times calls for desperate measures (not really, just sounded cool to write that)😁. It was time to employ the blow torch. My pyro son and I had been soaking the shaft with a penetrant hoping it would help. It didn’t and come to find out it wouldn’t have even if I’d of soaked it for years! I used the blow torch directly on the ‘collar’ for 5 minutes and then gave it 5 smart taps with a hammer. I then positioned the pry bar between what was left of the clutch and the shaft housing. Little by little the clutch started to come off. No loud ‘pop’ since it wasn’t a tapered shaft. When it finally came off you could see how much rust ‘welded’ the clutch to the shaft via the woodruff key. The key was also way out of position and there was no possible way to access it in order to remove the clutch. So, destructive as it was, I now know for certain how the secondary clutch fits on the drive shaft on a Hyundai cart with a Dana/Spicer differential and if I were to help someone in the future I know the steps to remove the secondary clutch, what tools to have at hand, and what to expect when I take a certain action.

[rikrikrik]

Crazy!!

[rlmobile]

it should have slid off in 1 piece like a ClubCar secondary. WTH?