I'm lifting the pony motor off of my D2-5U to see whats up with my starter pinion. I think it stuck in when the diesel started and something broke. I heard it brake. And, I think something could still be floating around in the clutch compartment although, I haven't found anything yet when I pulled the plug out the bottom. I can see in the top inspection hole and I don't like what I see. The 'gizzmo' on the end is loose and flopping around. There's definitely something haywire.
I'm to the point that I'm ready to take off the pony.I don't need to "reinvent the wheel" here. I don't have the time or the resources. I don't think the method they show in the book using two slings around the cylinders is for me..., it looks OK in the lab but I'm in the field. ( Really in the field, and racing winter) Hasn't anyone devised a lifting eye to bolt on that would be more positive? Also, I don't want to remove the maggie , carb., and or the governor.
The engine starts and runs to well to fool with any of it if I don't need to.
Also, I'd like to know how much the engine with the accessories weighs. I'm guessing 200#or less. Is that close? At any rate, It's to heavy for this Fat boy I'm sure.
Once I get the pony up and out of the way, I'll remove the pinion shaft the way the book says and hopefully I'll be able to determine what's wrong and see if there's any hardware in the bottom of the clutch compartment. Has any one had experience with this?
Another question here is, are the parts for this repair available readily?
I'm a rookie at this site and it seems like a wealth of information from some very knowledgeable people. If I mess this up after getting help from you guys, it'll be my own fault...

I am still have some use part for d2 poney cluch.

Just had my pony out for a rebuild. It is heavy, I used lifting straps without taking mag, govener off. I made sure that I wasn't pinching stressing any parts. Make sure you find all of the bolts / nuts holding the pony down, there is one on the left side (as viewed from the operators seat) that is VERY hard to get to. Gasket is still avalible for the base (got mine from Foley Cat in Kanasas) If possible get / make somthing to sling the pony from, it will help on install, lots of connections to make. Also when putting the nuts back on, I held the pony up some to give my hand more room to get to that one on the left side. Good luck) Tim

I was thinking about your post and having to manhandle that motor out of position (that could make for painful after efects)
Can you get a pickup close in then use a engine lift in the bed
The truck will do three things for you. 1 prevent the front wheels on the lift from sinking into the dirt 2 the bed will allow the lift to move alittle.
and 3 its always easier working downward ,not reaching up or over.
Thats all the help I can give lol.. greyhead

I have lifted the pony off by myself and it isn't a lot of fun. .some kind of lift would make it a lot easier.

With the end of the pinion control flopping around it sounds like the 1/2" ( I think) shaft that keeps the starter pinion control from rotating may nave broken. That broke on one D2 I had and as I recall, the only way to replace that is to split the engine from the transmission to get enough room to work on it. I replaced the one on mine with a piece of 1/2" (I think) cold rolled shaft.

After getting the broken chunk out of the control, I put the two pieces together to get the correct length of the new part. After shoving it in, I cross drilled and pinned it in.

I did this several years ago so my memory could be a bit foggy. .

Ol Grump,

Do you know why it broke? The D2 3J that I just purchased is broken as well. First one that I have seen. They all seem to be on the D2's. I think the parts are the same as the D4.

John

John,
Unfortunately I don't know why they break as they move straight in and out. The only bearing point against anything that rotates is the button on the end of the pinion. The one I fixed also had a torn up end and no button so I thought maybe that's what caused it. Maybe someone else has a better idea of what causes that. All I know is that when I examined the broken parts it looked like it had crystallized a little before it got bent.

"gemdozer" wrote:

I am still have some use part for d2 poney cluch.

To all,
Thanks for the replys. We actually was able to get the machine into the shop today and after a slight delay, we'll continue to work on it. I hope it wasn't stupidity on my part that broke the pinion. Maybe we will be able to tell once it's out...
JMc