5J D2 - Pony/Donkey Engine Removal - Pinion Gear Repair

Finning cat or KEP yes you will need to drain the engine coolant and oil from the starting engine ,

Thanks -

I got the starter engine and the pinion gear housing/assembly off today.


I've got a list of parts I want. The pinion gear assembly is soaking in some diesel overnight - we'll see how it cleans up.

Does anyone have the part number for the lock-shim and bolt arrangement shown on this video:

https://www.youtube.com/watch?v=lKI3wTZU4AA

My unit has the lockwire bolt assembly - I'd like to replace with the later locking shim.

Lock tab is 4H1351 - 2 of, lock capscrew is 4H1350 - 4 of

Neil - Thanks!

No problem - I actually just fitted them to my 5U's pinion tonight so they were fresh out of the Cat bag.

Today I disassembled the entire starter pinion assembly - which took more effort than I expected... The pinion gear was very seriously seized on to the splined shaft - requiring a lot of heat to shift it.


I'm hoping I can get some replacement latches, latch pins and adjuster screws as are mine are goosed.

I've not idea on the availability on likely any of these parts? I've mailed Finning and Kep for quotes. Fingers crossed..!

Also search for your part #s on machinerytrader.com. Some of those parts can be rehabilitated. You can put a nice straight edge on the latches again, and if the adjuster screws are not bent right out, you can run them through the die. The pins look generic so I'm sure a couple could be turned down pretty easily from mcmaster.com or somesuch. What's the adjuster spring like? When you reassemble, slather everything in anti-seize and fit new split pins. Cut most of the excess split pin off so you only have a quarter inch left to bend over. And shine everything up with your wire wheel/buffer.

Sadly the spring that is between the latches was broken into about 3 pieces. I've managed to extract the screws from the latches. A lot of the parts I'm looking for are listed in stock (albeit in the US or Aus).

Can't wait to get it back together! Its been too long since it last ran..

I've managed to track down most of the parts, however, I'm struggling to source:

6B1909 - SPRING
3B5464 - SPRING
4B7271 - LOCK
2B1864 - LOCK

Is it possible these parts were replaced with newer versions? I only have a D2 3J Parts book.



Photos:


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D2 CAT in bits

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Pinion gear / clutch housing removed. My unit was fully seized so could not latch it. Removal was quite easy with the diesel injector governor housing removed.

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pinion gear/clutch in bits

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some of the lock shims i want to refresh


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Latch spring (broken)