Advanced techniques for removing driven clutch??

[Doc's BoneCracker]

Originally Posted by IRCJB

Scabbed together a puller from old mower blades and some scrap.
I've put about as much pressure as I feel comfortable giving it; then backed it up with some hammer blows.

I'm running out of options that don't involve a cutoff wheel and a couple hundred bucks

I haven't applied heat yet since I'm not sure what I can get away with.

On your puller do you have a tightening nut or just this bolt? looks like you need to run the bolt thru a nut then the puller so when you get the puller bolt tight you then need to use an impact wrench and it might break free

[IRCJB]

Originally Posted by Doc's BoneCracker

On your puller do you have a tightening nut or just this bolt? looks like you need to run the bolt thru a nut then the puller so when you get the puller bolt tight you then need to use an impact wrench and it might break free

The nut is welded on the other side.
It will produce enough pull to bust a pulley.

Pull, heat, and tap just didn't work out this time.
Oddly enough, the puller had been sitting at the same tension for a while (smoke break). When I came back and started with the torch & hammer is when it cracked.

I skipped the pickle fork. I just had a gut feeling that with this one stuck so bad; I would wind up causing more damage with it.

[racin161]

Guess it's time for the pickle fork as it will apply the force closer to the center of the clutch and NOW with a big hammer. Not going to hurt anything. Let us know!

[IRCJB]

Originally Posted by racin161

Guess it's time for the pickle fork as it will apply the force closer to the center of the clutch and NOW with a big hammer. Not going to hurt anything. Let us know!

There's still bearings & transmission case to tear up. I'm already dumping $180 on a new 28* driven; so I'll just contain my losses there.
Judging by some other things I've seen on this cart, I think there's a good bit of rust gluing these parts together.

After all this trouble & expense, I'm hoping my performance problem really was in the secondary.

[882001]

Can you get Slide hammer to it?

[racin161]

28 is not going to do any good if you don't get it removed. Your call!!

[IRCJB]

Originally Posted by racin161

28 is not going to do any good if you don't get it removed. Your call!!

There's a "plan B" still to go.

I'll grind/cut a ring of Al off the end; exposing some of the steel insert. I'll then weld a 1/2" or 5/8" nut to that. Then it's fun time with an impact wrench and sacrificial bolt.

Plan C will be taking it off in pieces to get down to the steel; then cutting longitudinally to split it in half.
I'll need to do that last part before I get into the second pot of coffee.



Either way, I'll post pics.

[IRCJB]

Well, I never thought it would go this far. Really wasn't expecting to have a new set of matching EZGO paperweights.

First, I cut the end off, to expose the steel insert; so I would have something to weld a nut onto.
Pro Tip: make sure you put the spacer bolt in before welding a nut on.
Pro Tip 2: Thread chase the welded nut after it cools.



Things didn't work out so well. I don't know if it was just me being "off", the wind blowing my shield gas away, or the insert being made of some kind of stainless. The weld between the insert & nut broke twice. It did put up with a lot of abuse, but the Ingersol 231 torque won the fight.
So.....it's back to the cutoff wheel and surgical disassembly.

[IRCJB]

You can cut the outer sheave wherever you want. The goal is to split it open & disengage the groove at the end of the shaft.
I chose my cut based on the ribs being shorter and causing less interference with the cutoff wheel.


Once the outer sheave knocks off, things really fall apart. Measure and cut excess insert end off.

[IRCJB]

It was really boogered up in there. Spring looked OK, but I don't have another one around to compare tension. I'm wondering if those ramps are worn down enough that it was jumping.


There's a steel ring inside this last piece of aluminum. When the sparks start flying, you're not quite done yet.