Removing the drive clutch on a 1993 Club Car golf cart can be challenging without the proper tool. While a specialized clutch puller is recommended, some opt for a DIY approach. This article explores a personal experience with DIY removal methods and offers insights for those considering this route.
Several attempts were made using readily available materials. First, a 1/4″ round bar was tried but bent under pressure. A cut-to-length 1/4″ drill bit met the same fate. Fortunately, neither got stuck in the clutch. Slow, careful progress checks were crucial during these attempts.
Success finally came with a modified 1/4″ drive socket extension. The female end was cut off, leaving a length of approximately 5 5/8″. A 7/16-20 bolt was threaded into the clutch, and gentle pressure from a 2×4 aided in the removal. Minimal force was used to avoid further thread damage.
It’s suspected the original clutch threads were not 7/16-20, as they were stripped and required re-tapping to this size before removal. The original thread size may have been M12-1.25, but this couldn’t be confirmed after the re-threading.
The 3/8″ diameter of the 1/4″ extension proved slightly too large for the engine output shaft. It became lodged after applying torque and required careful extraction with needle-nose pliers after the clutch was removed. Thankfully, the extension came out easily without damaging the shaft threads. Ideally, a 5/16″ diameter tool would fit the 1 3/8″ deep output shaft perfectly.
While this DIY method worked in this specific instance, access to a machine shop was available as a backup if something went wrong. This highlights the inherent risks of DIY removal.
In conclusion, while DIY solutions for drive clutch removal exist, they come with potential complications. Stripped threads, stuck tools, and potential damage to the engine are real possibilities. The safest and most efficient approach is investing in the correct 1993 Club Car Drive Clutch Tool. This ensures a smooth removal process and minimizes the risk of costly repairs.
