Club Car Drive Clutch Removal Process

The Club Car drive clutch is an essential component of the golf cart’s transmission system, responsible for transferring power from the engine to the wheels. Over time, the drive clutch may become worn or damaged and require removal for repair or replacement. This guide outlines the step-by-step process for removing a Club Car drive clutch. Remember to consult your owner’s manual for any specific details related to your golf cart model.

Tools and Materials:

1. Socket wrench set
2. Flathead screwdriver
3. Clutch puller tool (specific to Club Car models)
4. Protective gloves
5. Safety glasses
6. Clean cloth or rag

Step-by-Step Club Car Drive Clutch Removal Process:

1. Prepare the golf cart: Park the golf cart on a flat, level surface and turn off the engine. Engage the parking brake and remove the key from the ignition.
2. Allow the engine to cool: If the engine has been running recently, wait for it to cool down completely before proceeding.
3. Disconnect the battery: To avoid any accidental electrical issues, disconnect the battery by removing the negative cable first, followed by the positive cable.
4. Access the drive clutch: Remove any covers or guards that may be obstructing access to the drive clutch. This may involve removing the seat or other body components, depending on your specific model.
5. Inspect the drive belt: Before proceeding with the removal of the drive clutch, inspect the drive belt for wear or damage. If it shows signs of wear, consider replacing it along with the drive clutch.
6. Remove the drive belt: Loosen the drive belt tension by either loosening the tensioner bolt or, if your model does not have a tensioner, sliding the driven clutch towards the engine. Once the belt is loose, slide it off the drive clutch.
7. Remove the clutch bolt: Using the appropriate socket wrench, remove the bolt securing the drive clutch to the engine crankshaft.
8. Install the clutch puller: Thread the clutch puller tool into the drive clutch’s threaded hole, ensuring it is firmly seated and properly aligned with the crankshaft.
9. Remove the drive clutch: Using a socket wrench, turn the clutch puller tool clockwise to apply pressure on the crankshaft. This will force the drive clutch to separate from the crankshaft. Be patient, as it may take some effort to break the clutch free. Always wear safety glasses and gloves while performing this step.
10. Clean the crankshaft: Once the drive clutch is removed, clean any debris, dirt, or grease from the crankshaft using a clean cloth or rag.

Required Tools

Tool Name	Size	Quantity	Purpose
Socket Wrench	9/16 inch	1	To remove bolts on clutch cover
Torque Wrench	50 ft-lbs	1	To tighten bolts after reinstallation
Clutch Puller	N/A	1	To remove drive clutch from shaft
Snap Ring Pliers	N/A	1	To remove snap ring from shaft
Flathead Screwdriver	N/A	1	To remove cover screws

Clutch Cover Removal Steps

Step Number	Step Description
1	Turn off engine and place vehicle in neutral.
2	Remove the four bolts securing the clutch cover using a socket wrench.
3	Pry off the clutch cover using a flathead screwdriver.
4	Set the clutch cover aside in a safe place.

Drive Clutch Removal Steps

Step Number	Step Description
1	Remove snap ring from shaft using snap ring pliers.
2	Screw the clutch puller onto the end of the drive clutch.
3	Tighten the clutch puller until the drive clutch comes loose.
4	Remove the drive clutch from the shaft.

Drive Clutch Inspection

Inspection Item	Acceptable Range	Inspection Procedure
Clutch Shoe Wear	0.125 in – 0.5 in	Measure thickness of each clutch shoe. Replace if outside range.
Clutch Spring Tension	110 – 120 lbs	Use a spring compression tool to measure tension. Replace if outside range.
Clutch Sheave Runout	0.003 in or less	Use a dial indicator to measure runout. Replace if outside range.
Clutch Shoe Hub Wear	0.125 in or less	Measure thickness of each clutch shoe hub. Replace if outside range.
Clutch Roller Wear	0.125 in or less	Measure thickness of each clutch roller. Replace if outside range.

Clutch Reinstallation Steps

Step Number	Step Description
1	Clean the clutch shaft and clutch threads with a rag.
2	Apply a thin layer of anti-seize lubricant to the clutch shaft threads.
3	Place the drive clutch onto the clutch shaft.
4	Tighten the drive clutch onto the clutch shaft with a torque wrench to 50 ft-lbs.
5	Install the snap ring onto the clutch shaft.
6	Install the clutch cover and tighten the bolts with a socket wrench.
7	Start the engine and test the clutch operation.

Drive Clutch Torque Specifications

Bolt Type	Torque Specification
Clutch Retaining Bolt	55-65 ft-lbs
Clutch Cover Bolt	20-25 in-lbs
Snap Ring	N/A

Symptoms of a Faulty Drive Clutch

Symptom	Possible Cause
Sluggish acceleration	Worn clutch shoes or springs
High RPMs but low speed	Worn clutch sheave or rollers
Burning smell	Overheated clutch
Clutch slipping	Worn or damaged clutch
Loud or grinding noise	Worn or damaged clutch or sheave

Safety Precautions

Safety Precaution	Description
Wear gloves	To protect hands from sharp edges or hot parts
Disconnect battery	To prevent accidental starting of the engine
Block wheels	To prevent vehicle from rolling
Use jack stands	To secure the vehicle while working underneath
Work in a well-ventilated area	To avoid inhaling harmful fumes

Conclusion:

With the Club Car drive clutch removed, you can now proceed with repairs or replacement as needed. When reinstalling the drive clutch or any other components, be sure to consult your owner’s manual for torque specifications and proper installation procedures. Regular maintenance and inspection of your golf cart’s drive system will help ensure its longevity and optimal performance.