116-1605 PTO Clutch Replacement | Warner 5218-167, 5218-208, 255-4520

Overview

This aftermarket 116-1605 electric PTO clutch replacement is designed for mower applications using the Warner 116-1605 / 255-4520 clutch path. It also replaces Warner 5218-167, which Warner identifies as superseded by 5218-208.

Built for heavy-duty mower applications, this clutch restores electric blade engagement and controlled blade stopping when the original clutch matches the same mounting, bore, pulley, rotation, connector, and belt arrangement.

This PTO Direct USA replacement uses a 1-1/8-inch crankshaft bore, 7-1/4-inch pulley diameter, clockwise rotation from the pulley side, and a reverse-mount configuration. Confirm the complete original clutch number and physical fitment before ordering.

Specifications

• Crankshaft Bore: 1-1/8 inches / 1.125 inches
• Pulley Diameter: 7-1/4 inches / 7.25 inches
• Rotation: CW clockwise from the pulley side
• Mounting: Reverse mount
• Voltage: 12V DC
• Clutch Function: Electric clutch with integrated brake
• Torque Class: 200 ft-lbs
• Connection: Integral electrical connector; flat side-by-side at clutch with option wire harness extension to T-plug

Key Features

• Aftermarket electric PTO clutch replacement
• Fits the Warner 116-1605 / 255-4520 / 5218-167 / 5218-208 number path
• 1-1/8-inch crankshaft bore
• 7-1/4-inch black pulley
• Clockwise rotation from the pulley side
• Reverse-mount configuration
• Integrated brake for controlled blade stopping
• 12V DC electrical operation
• Fully assembled replacement clutch

Compatible Applications

This clutch is for select commercial mower applications that identify one of the part numbers listed below. Warner’s 5218-208 page does not establish universal model fitment, so this listing is build around the manufacture number that are used across multiple brand names.

Confirm fitment by matching a Warner label number from the original clutch.

For fitment support before or after ordering, send the mower model and serial number, the original clutch number, and clear photos of the pulley side, mounting side, connector, and crankshaft bore through our Parts Desk.

Replaces Warner Numbers

• Warner: 116-1605
• Warner: 1161605
• Warner: 255-4520
• Warner: 2554520
• Warner: 5218-167
• Warner: 5218167
• Warner service replacement: 5218-208
• Warner service replacement: 5218208

What’s Included

• Complete electric PTO clutch and integrated brake assembly
• 7-1/4-inch pulley
• Pre-installed bearing assembly
• Integrated electrical connector
• D-spacer bushing and flat washer
  
• Optional wire harness extension

Common Symptoms of a Failing PTO Clutch

• Mower blades will not engage
• Clutch clicks but the deck belt does not turn
• Blades engage cold and stop after the clutch warms up
• Grinding, rattling, or bearing noise near the clutch
• Burning smell or excessive clutch heat
• Intermittent connector or wiring failure
• PTO fuse repeatedly blows during engagement

Why Buy From PTO Direct USA?

• Fast USA shipping
• Fitment guarantee
• Fitment support before and after purchase
• Clear product photos for easier clutch identification
• Trusted replacement supplier for homeowners, repair shops, and mower service professionals

FAQ

What replaces Warner 5218-167?

Warner identifies 5218-208 as the replacement for 5218-167. This aftermarket listing follows that same Warner number path and also cross-references Warner 116-1605 and 255-4520.

What is the bore size?

This replacement uses a 1-1/8-inch bore. It is not a 1-inch-bore clutch.

What rotation does it use?

This clutch uses clockwise rotation when viewed from the pulley side.

What does reverse mount mean?

Reverse mount identifies the clutch’s engine and deck orientation. Compare the mounting face, anti-rotation restraint, pulley offset, and connector position with the original before ordering.

Is the 7-1/4-inch pulley the same as Warner’s 7.39-inch measurement?

Warner lists 7.39 inches as the flange outside diameter on its 5218-208 specification page. This aftermarket replacement is specified with a 7-1/4-inch pulley. The critical spec is where the belt actually rides in the pulley groove. Small variance in outer flange diameter measurements are common with aftermarket clutches.

Can PTO Direct USA help confirm fitment?

Yes. Send the complete mower model number, serial number, original clutch number, and clear photos to the Parts Desk. Include photos of the pulley, mounting side, connector, anti-rotation arrangement, and crankshaft bore.

Need a different fitment? Browse the full electric PTO clutch catalog.