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Broken Clutch Puller

M

M-ATE

New member
The other day I was trying to take off my primary on my 07 M8 and my clutch puller broke at the threads and is currently stuck in my primary. What tips or suggestions do you have to either get the puller out or the clutch off. I've tried heating the primary up with a propane torch and pounding on it with a mallet but it hasn't popped yet. Perhaps I need to add more heat? Someone suggested an easy out but that was a waste of time because there is too much pressure on the puller and the easy out is tiny. I've also added quite a bit of penetrating oil to the back of the clutch and tipped the sled on its side to let it hopefully penetrate down the shaft.
 
any chance it's sticking out enough to weld?other choice may be one of the reverse bits but like you said lots of torque good luck lets see the idea's!
 
Frie it up and put some tension on the belt, It might just pop the clutch off.
 
I would not focus on getting the clutch off, personally.

If you can drill the puller, you have a few options.

- Use a large easy out (they do make large ones)
- Get a left handed tap and tap some threads in the puller, then use a left handed thread bolt and run it in

Once you have the old puller out, teflon tape the threads of the new puller and use a little water in the clutch hole. You'd be surprised how well it works.
 
If it's already that tight, how about heat to the center hub and hit the broken end of the puller with something.
 
Blk88GT said:
Once you have the old puller out, teflon tape the threads of the new puller and use a little water in the clutch hole. You'd be surprised how well it works.
Click to expand...

the water trick is the only way i can get mine off, and it take only about half the pressure on the puller.
 
Broke puller

Mine did the same thing on my doo last year fire up the kettle and pour water on the centerwere the belt rides at idle and it should pop right off.
 
Yes, put the sled on it's side. My wife loves helping with this, honest ;)
 
Well I've tried a lot of heat and penetrating fluid numerous times and that hasn't worked. I took it to a buddy who's a cat dealer and he tried a bigger easy out and that didn't work either. I also ran it to load it up in my truck and was hoping it would pop off then.

I called around town and no one sells left handed taps or bolts so I can't easily get one but I will be looking on the internet. So the only thing I have left to try is dumping hot water on the shaft inside the sheaves while it is running. With the clutch spinning is it really going to make that much difference? Either way I'm pretty much out of options for now so it is worth a shot.
 
M-ATE said:
The other day I was trying to take off my primary on my 07 M8 and my clutch puller broke at the threads and is currently stuck in my primary. What tips or suggestions do you have to either get the puller out or the clutch off. I've tried heating the primary up with a propane torch and pounding on it with a mallet but it hasn't popped yet. Perhaps I need to add more heat? Someone suggested an easy out but that was a waste of time because there is too much pressure on the puller and the easy out is tiny. I've also added quite a bit of penetrating oil to the back of the clutch and tipped the sled on its side to let it hopefully penetrate down the shaft.
Click to expand...

I had a friend do that on a old polaris years ago...propane wont get it hot enough..you need a acetelene torch, a big hammer and a long drift..heat the hub up hot and then sneek the drift in as close to the base of the clutch on the back side between the case and clutch..hit it hard till it pops off...otherwise put a belt on it and go ******* it on some grass till it pops off..
 
You need an acetelene torch with a rosebud tip. You have to throw a lot of heat into the hub fast. If you heat it too slow the heat gets to the crank and that swells tight. It can take your crank seal out too. Heat the clutch hub fast, put a large punch on the bolt and give it a few good hit with a hammer. It should come off. You could also try taking the cover off the clutch, bolting a heavy plate to the clutch and use a heavy slide hammer on it. If everything fails you may need a cutoff tool and cut the clutch off. Hope it does'nt come to that.
 
As you were tightening your puller, were you taking time to pound on it? With my experiences, the clutch has popped off after a few good whacks rather than keep tightening and tightening. Have you tried lining up a punch with the piece of the puller stuck in your clutch and giving it a few good shots? If not, give it a try. I would suggest a brass punch so you don't scar things up. Good luck.
 
colorado_matt said:
As you were tightening your puller, were you taking time to pound on it? With my experiences, the clutch has popped off after a few good whacks rather than keep tightening and tightening. Have you tried lining up a punch with the piece of the puller stuck in your clutch and giving it a few good shots? If not, give it a try. I would suggest a brass punch so you don't scar things up. Good luck.
Click to expand...

Sounds like he broke the puller off flush with the threads in the clutch. :(

I would try the slid hammer idea. Take the clutch apart and fabricate an adapter that will hook onto the cover holes. Or maybe pull the spider and get ahold of the center of the clutch. All these options would be a pain in the sled.

Like it was said before. If you try and heat the clutch to pull it you have to let it cool completely and every wrap the center of the clutch with ice to make sure it is as cold as possible. Then hit it with the heat. And make it quick. If you the crank starts to swell you are stuck.

After that you are down to a die grinder.

Thunder
 
I don't know how much damage that has been done when you drilled for the easyout. Whenever I run into a broken bolt like that I make sure that the hole I drill is exactly centered, (or as close to that as possible). Then you can keep drilling it out and trying ever bigger easyouts. If you cannot get it with the easyouts you can drill it out to the tap size and pick the threads out with a dental pick. I find it's easier to use a lot of care rather than being brutal with it. If you run the engine and the clutch pops off the belt may jam and you could damage, (bend), the crank. Also I'm not a big fan of using a hammer or slide hammer, too hard on the crank and bearings.
 
as for removing the broken bolt i would suggest what other's have said - use a hot torch to quickly heat the center of the clutch and then give some hard wacks to the broken puller.

For future use, i've found using grease on the front of the tip of the puller works very well, no need to turn the sled on its side this way either. Pops right off and helps to keep the tip from binding once it bottoms out on the crank. :D
 
Got the clutch off today using a lot of heat. Now my question is has all that heat fatigued my clutch at all? The part that was heated is discolored and I'm wondering if I have anything to worry about?
 
M-ATE said:
Got the clutch off today using a lot of heat. Now my question is has all that heat fatigued my clutch at all? The part that was heated is discolored and I'm wondering if I have anything to worry about?
Click to expand...

more then likely the clutch is ok...any time you heat steel it will blue...to be safe I would have the clutch checked for balance but should be ok..now did you get the broken puller bolt out? if not ...hold a big nut up to it and weld thru the center of the nut onto the end of the broken bolt..building out onto the nut..once welded good and while still hot..spin it out with a impact...if it breaks the nut off grab another and do it again till it comes out...once it is out let the crank air cool to touch and then run a tap thru it to clean the threads....and use a turque wrench when you reassemble(lots of peeps use way to much torque on clutch bolts)
 
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