D2 5J pony engagement problem

Hey all,

I finally got the D2 pony running tonight. Just needed to get the plug wires right, enough fuel in it, and pull the cord for an hour!

I can't seem to get the pinion engaged. The clutch lever appears to be stuck, while the pinion lever feels like it's loose and not attached to anything. In fact, I can pull up the pinion lever and hand-turn the pony and nothing engages.

Any ideas where to start?

Thanks,
Sam

open up the clutch inspection cover and look at the engagement rod and finger etc with a flashlight and mirror if necessary.

Also may be able to see something through the adjustment cover over the pinion near the left brake pedal.

I had the same problem on a D2 7J that I'd bought as a parts donor. What had happened was that the rod on the engagement finger had broken and wouldn't position the finger so it could push the pinion in. Unfortunately the only way to fix that is to split the diesel from the tranny. I removed the broken pin and found the rest of the pin in the bottom of the flywheel housing, measured the total length and used a chunk of 1/2" cold rolled 1045 shafting to replace the durned thing. The broken pin will come out of the finger, just weld a 5/8" nut to it, then start twisting and pulling at the same time. Locktite the new pin in and you're ready to put it all back together.

I later replaced the parts I'd taken off the donor machine, put it back together and sold it

I hope that isn't what happened but be prepared for the worst.