Driven clutch / secondary clutch disassembly for John Deere Gator 6x4

What you really need to do this is a lot of HEAT to soften the Loctite on the set screw, but that step is not mentioned in the Technical Manual. The full procedure is spelled out in TM2239 in the Power Train Repair section, Driven Clutch Disassembly and Assembly. At this writing, that manual was not available on the web. However, the procedure is also on page 519 of TM1518, which can be found on the web.

Interestingly, the TM1518 has a “Secondary Clutch Spring Torsion Check” on page 511 to check whether the spring force is within spec. That procedure is not in the TM2239. The clutches are different, which may be why.

Text of procedure from TM2239 is:

Driven Clutch Disassembly and Assembly Disassembly:
1. Mark location of set screw (A) on the outer edge of the cam (B).
2. Place alignment marks (C) on cam and movable sheave to aid in assembly.
3. Mark the location of the spring tab in the movable sheave (D).
4. Remove set screw (A). A Caution: Avoid Injury! Hold cam securely to prevent sudden spring release Note: Cam is press fit on shaft. Use a three-jaw puller and an impact wrench, at low speed, to remove cam from shaft.
5. Use a three-jaw puller to pull the cam off of the shaft.
6. Remove cam, spring, and movable sheave from shaft.

Inspection: Note: Ramp buttons are mounted with tabs on backside. Tabs are interference fit into holes on face of ramps. Remove buttons only if replacement is necessary.
1. Inspect ramp buttons (E) for wear or cracks.
2. Inspect the ramps (F) for nicks or scratches.
3. Inspect sheave shaft (G) and bore (H) for wear, nicks, or scratches.
4. Inspect movable sheave seal (I) for wear or damage.
5. Replace any damaged components as needed.

Assembly:
1. Install movable sheave on fixed sheave.
2. Install spring. Insert spring tab into previously marked hole in movable sheave and hole in cam.
3. Align set screw bores (J) and press cam on shaft until cam lobe almost touch ramp buttons (E).
4. Rotate the movable sheave until the marks (C) are aligned and continue to press the cam onto the shaft until fully seated.
5. Apply thread lock and sealer (medium strength) to threads of set screw (A) and install.
6. After clutch in installed, check clutch operation. See "Driven Clutch Back-Shifting Check" on page 490.