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I guess it’s time I ask on a Gator forum rather than keep guessing! My uncle has an older Gator 4x2 (not sure of the model number or year, we couldn't find it while looking) and he needs to replace the secondary clutch. He got it when he moved into a new house last year, and it needed a little work. One of the issues seems to be that the bolt holding the secondary/driven clutch to the transmission backed out and totally destroyed the clutch, warping it on the shaft. It seems to be just the clutch that is damaged, but I can’t know for sure until we can remove it.
He has a new clutch for it along with the belt, however we couldn’t figure out how to get the old one off. We tried various methods of prying, air hammer, nearly a whole can of PB blaster, etc. It’s extremely seized!

I’ve seen various pullers using a bolt and some sort of dowel, whether it’s a cut off bolt shank or whatever other material, but if I’m not mistaken, that is for the primary clutch. It doesn’t look like there is any threading within the clutch to be able to use that method. I’m not sure what else to do other than heat it up really well or try to find a very large 3 jaw puller. I’d have to figure out how to make room for the latter.

Now forgive me, it’s been almost a year since I’ve worked on it, so I don’t remember the exact state we left it, but I know we ended up hacking up the pulley pretty good. Other projects have taken priority, but I really want to help him get his Gator back up and running now that the weather is getting nicer... so here I am!

Here are a couple pics. It does look like the bolt had just backed out, no evidence of it snapping. It looks hacked up on the front, but I was prying against the transmission case, not on the face of the pulley.

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Brainstorming: perhaps drill and tap holes in the thicker section outside the counterbore for attachment screw and use a harmonic balancer puller.
 
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You might try to super cool the shaft with a bolt freeze off product ? Otherwise you may have to try to either pull as you mentioned or try taking the clutch apart as far as you can and then freeze or heat the shaft... it’s not going to be pretty..
 

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Just curious is the secondary clutch not working the reason why the gator would crank right up and go into both gears just doesn’t actually move? The spring was outside of the secondary clutch and I believe that is the issue.
 

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I like that idea... I might have to give that a go. I have a decent right angle drill that would work well for that.
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Howdy folks.
Whatever model yours is it's the same as mine. I call mine a John Deere Utility Vehical. I think mine was manufactured before they came up with ( Gator ).
I'm still working on getting the left handed thread bolt out of my secondary unit.

I can tell you this. I'm 57 and own a 1970&1/2 TransAm. And have been racing all my life so when I ran across a dual shaft, horizontal 23.5 hp Kohler stroked to,,, I believe it's 47 hp. I bought it and threw it right on my Utility vehicle. I think factory top end was 11. I hit almost 60 mph before the ??? Transfercase is that what it's called? Locked up. They are around $4,300.00 around here. I would watch getting the secondary shaft very hot unless you plan on putting a seal kit in yours. One would think if you only used a propane torch, then quenched it fast or used can air upside down to cool it down kick, it would knock off with a 8 pound sledge hitting a pipe from other side but be sure you don't bend that shift.


I have every different puller ever made. I'll take a look and see if I can't suggest one.

In the meantime, best of luck.

Dan G.
 
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