My D6 9U pony motor recently gave out. It looks to me like one of the cotter pins that help hold the rod cap nuts came out, and allowed one of the rod nuts to back off. Pistons and rings look fine, but the one rod and crank are no longer usable. I am looking for replacements, and have at least one good lead on the parts.

I have the pony removed, and nearly all torn down. The problem that I have right now is that I am not able to get the 18T gear (4B2256) removed from the front end of the crankshaft in order to remove the crankshaft. There is no room to get a gear puller behind the gear. They give you small 1/4" threaded holes in the gear to use for pulling, but the holes are so small that 1/4" bolts aren't providing enough strength for me to get it pulled. Now I have one broken off 1/4" bolt in one of the holes of the gear, and a gear that won't come off . Does anyone have any suggestions, or am I missing anything? Thanks.

Possibly if you can get the broken bolt out you could use new ones and put some heat to it might let it pull off then.I have pulled dozens of them off and at the shop we had a tapered edge puller that would go in narrow places but I can,t remember if I ever used it on the crank gear or not as it is pretty close behind it.

Thank you, SJ. You have been a help many times. I got the gear off with the help of a good dose of heat and a few pry bars/chisels pounded behind the gear. Now I can go to rebuilding.

Now, I am getting ready to reassemble this pony motor. I have a different crank, rods, caps, main and rod bearings to put in. Is there any specific way to install the rings in relation to each other? Do you just offset the ring gaps? Any other tricks or "must do" techniques to reassembling this thing? Thanks.

I have rebuilt a truck load of them and I always positioned the first ring installed just off center of the wrist pin hole and the next one staggered over on the other side of the piston (180 D.) just off the pin bore etc. and they worked out well that way.I never liked to position some of them on the bottom or top of the cyl. bore but always like I mentioned above.