From what I can see, the clutch threads on my EZGO TXT golf cart are completely stripped, and it’s really affecting the performance. I’ve tried a few things, but nothing seems to work. Has anyone else come across this issue before?
Response
It was a bit of a process but using helicoils to create new, stronger threads in the stripped area worked for me. I did this on my Club Car DS, but it should work on any type of golf cart.
Solutions that Worked for Users:
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Helicoils | 5 | 30-50 | 60-90 |
| Plastic Fillers | 3 | 10-20 | 30-60 |
| Longer Bolts for Floor Mat Retainers | 2 | 5-15 | 20-40 |
| Rivet Nuts or Brass Threaded Inserts | 1 | 20-40 | 45-75 |
Symptoms:
- Clutch threads on the golf cart are stripped.
- Difficulty in engaging or disengaging the clutch.
- Reduced performance and reliability of the golf cart.
Possible Causes:
- Wear and tear over time.
- Over-tightening of the clutch.
- Using incorrect tools or methods for clutch maintenance.
Solutions that Worked:
- Helicoils
- What I Did: Used helicoils to create new, stronger threads in the stripped area.
- Outcome: The clutch engagement became smooth and reliable again.
- Personal Experience: After installing the helicoils, the clutch felt like new. It took some time, but it was worth it.
- Estimated Cost: $30-50
- Time Needed: 60-90 minutes
- Steps:
- Identify the size of the stripped threads.
- Purchase the appropriate size helicoil kit.
- Clean the area thoroughly.
- Drill out the stripped threads with the specified drill bit.
- Tap the new threads using the provided tap.
- Install the helicoil insert into the new threads.
- Test the clutch for proper operation.
- Expert Tip: Ensure the helicoil is installed flush with the surface to avoid any imbalances or further damage.
- Plastic Fillers
- What I Did: Applied plastic fillers to rebuild the stripped threads.
- Outcome: The threads were restored, allowing proper clutch operation.
- Personal Experience: The filler needed to set properly, but once done, it held up well.
- Estimated Cost: $10-20
- Time Needed: 30-60 minutes
- Steps:
- Clean the stripped area thoroughly.
- Mix the plastic filler as per instructions.
- Apply the filler to the stripped threads.
- Allow it to set and harden.
- Re-thread or drill as necessary.
- Test for stability and function.
- Expert Tip: Be precise with the application to avoid excess material, which can cause misalignment.
- Longer Bolts for Floor Mat Retainers
- What I Did: Replaced the existing bolts with longer ones to compensate for the stripped threads.
- Outcome: The floor mat retainers were secured effectively.
- Personal Experience: A simple and quick fix that provided a temporary solution.
- Estimated Cost: $5-15
- Time Needed: 20-40 minutes
- Steps:
- Remove the old bolts.
- Measure the depth of the stripped hole.
- Purchase longer bolts that fit the existing diameter.
- Install the new bolts carefully.
- Ensure the retainers are firmly in place.
- Expert Tip: Check the bolt length to ensure it doesn’t interfere with other components.
- Rivet Nuts or Brass Threaded Inserts
- What I Did: Installed rivet nuts or brass threaded inserts into the stripped holes.
- Outcome: Provided a durable and long-lasting solution for the stripped threads.
- Personal Experience: Required some effort to install, but the results were solid.
- Estimated Cost: $20-40
- Time Needed: 45-75 minutes
- Steps:
- Determine the appropriate size of the insert.
- Drill out the stripped hole to fit the insert.
- Install the insert using the appropriate tool.
- Test the insert for stability and strength.
- Expert Tip: Ensure the insert is aligned correctly to avoid cross-threading.
Golf Cart Models Where This Worked:
- Various models, including EZGO TXT and Club Car DS, but specific years were not mentioned.