I have a 1997 425 magnum 2x4. The drive clutch lost two
out of three ramp buttons. The screws broke off inside the
housing. I tried drilling it out with a 5/64 drill bit
and use an ease out (s.p.), I can't get the broken screw
out. I was on the verge of making a mess out of it, so
I quit, I didn't try to remove the second broken screw.

anybody have any suggetions?

 

Seems to me, the only threaded portion is inside the button. If I'm understanding you correctly, you should be able to disassemble the clutch (have someone who is familiar with them do it for you, if you don't know how to) and use a punch to drive the broken screw stud out. It's difficult w/o visual to totally understand. Don't bother trying to save the buttons, they're inexpensive to replace. Hope this helps, but I can't emphasize enough to have someone who is familiar with clutch servicing to show you your first time....not saying you can't go it alone, it just helps.

Ken

 

Modquad,

Thanks for your response. The screws that broke are the ones that hold the buttons to the housing. The problem is that this location
is so deep into the housing, it is hard to get any tools in there.
and also the screws are broken off so deep in the hole that I
can't get a punch in there.


Thanks

 

I had this happen too i used JB weld to put the button in. I know it wil be a bugger to get out but i plan on a roller action clutch when i find a good used one.Oh yea it has been in like that for 6 months now.

 

I've done this a few times, use a drill press to drill out the broken screw, you won't get it out any other way, retap the hole and replace all the screws making sure they and the buttons are tight. They are self tapping screws and the ones that break are not holding the button tight to the clutch, the button rocks in the pocket and eventually breaks the screw.

 

Powerslider and ftwflh,

Thanks for the information. What I tried to do was use a a left-
handed(reverse cut) drill bit, hoping that it would unscrew the
broken screw. That didn't work, it just drilled through the broken
screw. Then I tried forcing an allen screw into the new hole, and
back it out that away, that didn't work either. I gave up, went to
the hardware store and bought the next size screw, tap and drill bit.
Drillled, retap and put in larger screws. What a mess, hopefully
the larger screws will be stronger than the stock size.

I was wondering it I should use locktight on these screws?


ftwflh,

You said that you used JB Weld to hold the buttons in. Was this
JB Weld only, without any screws?


thanks

John

 

I drilled out (or wolered out) the hole and put JB Weld in it and used the screw and button.