D2 Pony Pinion Issue

The pinion engage lever moves a rod with a "finger" on the end of it which pushes the pinion into engagement with the ring gear. Sometimes the "finger" will crack and break or maybe the other end of the lever (inside the housing) too. There is also a guide pin to align the "finger", possibly the guide pin fell out and the finger is misaligned. Unfortunately, about the only way to fix it is to pull the engine.

To pull both the diesel and the pony? I don't suppose there's another trick such as going in through the front by the clutch, or through the ~3" diameter inspection port by the left brake pedal? I only ask as the Cat's on a job, in about knee deep mud... where all cats belong!

The 3" cover plate is for adjusting the pinion latch springs, you might be able to see what's wrong in there but not enough room to work on it, same goes for the clutch adjust cover. If you remove the pinion assembly (that requires raising the pony motor a couple inches but you're better off to remove it completely) you might be able to get the engagement rod & lever out, but I've never tried that.

Yep, just as you said, we're going to have to pull the motors. Spent most of the afternoon working on getting the cat into position so we can use the loader to skid it onto our low boy in the morning. Oh what fun it is to work in knee deep mud!

Woa, I can feel your pain.

I once had a '38 D2 and had to replace the clutch in it. When I got it apart I noticed that the pinion "finger" had been welded at some point. I sold it in '97 and several years later some guy called me out of the blue and said that he owned the D2 now but the pinion won't engage. Luckily, my "warranty" had ran out and it didn't cover that anyway!

Here is what happened on my 4U model D2. That brass bushing had fallen out and allowed the finger to move into the spinning pinion and bent it.

For years I just stuck a pry bar in through the inspection hole to snap the pinion in before I started the pony. Its located under the left floor/foot plate.



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I have a D2 1941 the owner before me changed to electric. This is probable easier than repair.
At 74 years I love electric start.
Gene Walker

Gene--Was there glow plugs added also? I always thought that glow plugs were needed on an electric start to get the diesel fired off? Any idea on the relative rpm of the diesel on pony vs electric start?

Well, we spent almost 10 hours getting the dang thing up on a trailer today to take it to our neighbor's shop to pull the engines. Quite the ordeal! It took our self loader, 3 broken come-alongs and a 12v 12k# winch to get it up and in place. I guess tomorrow we'll see how easy the engines unbuckle and things come together!