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Old 04-16-2012, 10:37 AM   #1
Joerob25
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Default Broken/Stuck Driven Clutch

I've got a 2001 Club Car DS, bought both new clutches. i've gotten the secondary off and changed out just fine, however, the driven/main clutch is jacked up. i got the bolt off, and used a clutch puller bolt but the bolt head broke off with a slight turn from me. I'm not sure if it was defective from the dealer or not. But now i've got a broken bolt stuck in the clutch and can't get the clutch off still or the bolt out? Any ideas on how to get the clutch off?

I can actually still drive the cart with the bolt stuck in it believe it or not.
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Old 04-16-2012, 11:48 AM   #2
Joerob25
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Default Re: Broken/Stuck Drive Clutch

Sorry this is the main "drive" clutch. I have the new clutch so i'm keen on saving this old one but i don't want to damage the shaft getting the old one off but i don't care if i have to destroy it either, just want it off and my new one on.
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Old 04-16-2012, 01:01 PM   #3
fastercarter
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Default Re: Broken/Stuck Driven Clutch

Three or four jaw puller would be one option. You might be able to rent one from your local NAPA or whatever you have in your area. A hydraulic puller would be better but I don't see those much these days. Those clutches can be very stubborn at times and there seems to be a lot of posts regarding broken clutch removal tools. Maybe the Chinese are knocking them out with substandard materials and the sellers of the tools are unaware ? IDK but there are a fair few stories such as yours right now.

FC
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Old 04-16-2012, 01:08 PM   #4
simple man
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Default Re: Broken/Stuck Driven Clutch

If you have access to a welder, weld a nut to the broken bolt. the heat will also help to loosen it. If no welder, pick up a set of " E - Z Outs " and drill though the broken bolt and then use them. Welding a nut on is a much preferred method of removal, though!
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Old 04-16-2012, 02:25 PM   #5
Joerob25
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Default Re: Broken/Stuck Driven Clutch

fastcarter: ive got a bigger 3 jaw puller but the pulley is so close to the engine i can't get the lips of the fingers to go over that to pull it out.

also when i drive around on the cart, the clutch stays fixed in one position the entire time. It's one speed when you hit the gas....GO!
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Old 04-16-2012, 02:37 PM   #6
Joerob25
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Default Re: Broken/Stuck Drive Clutch

fastcarter: ive got a bigger 3 jaw puller but the pulley is so close to the engine i can't get the lips of the fingers to go over that to pull it out.

also when i drive around on the cart, the clutch stays fixed in one position the entire time. It's one speed when you hit the gas....GO!
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Old 04-16-2012, 02:38 PM   #7
Joerob25
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Default Re: Broken/Stuck Driven Clutch

anyone use the 2x4 method before? How does that work?
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Old 04-17-2012, 07:16 AM   #8
Joerob25
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Default Re: Broken/Stuck Driven Clutch

got the old clutch off with the 2x4 method! How easy! Thanks for the reads and comments guys, this is an awesome site......
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Old 04-17-2012, 09:44 AM   #9
Hardatwork
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Default Re: Broken/Stuck Driven Clutch

What is the 2x4 method
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Old 04-17-2012, 03:04 PM   #10
Joerob25
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Default Re: Broken/Stuck Driven Clutch

I took a small 2x4 about a foot or so long and put the the flat side on the angled side of the clutch and gave it a good two wacks with a big hammer. Rotated the clutch about 1/4 and did it again and kept going around until it finally started moving then slide right off. I didn't beat it hard but good firm hits twice and rotate 1/4 about 15 or so times and it came off with no issue. Patience worked and the new clutch went right on with no problem.
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