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D2 pony starter driven gear teeth

D2 pony starter driven gear teeth

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Ccafer
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Location: Rochester. NY
Posts: 23
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Can I get opinions on the condition of the teeth on this gear? After finally figuring out how this and the pulley were pressed on the bearing (this is the older style, 3 -bolt version), I was able to clean it up and get a good look at it. The condition of the now replaced bendix is pretty self-explanatory. Would anyone consider reconditioning the teeth, replacement or just leave it alone. It goes without saying that there is quite a bit more gear engagement with the new bendix.

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Sat, Feb 14, 2026 2:56 PM
Busso20
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Ccafe, are you able to turn the gear around to re-use? I would if possible, getting new would be the best, you would have to work out how much it gets used to turn or replace, I would think it will be heat treated to have the teeth last so a tooth repair will need to have heat treatment completed or they would be soft.

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Sat, Feb 14, 2026 10:42 PM
ctsnowfighter
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I see no reason you could not take a grinder and cut those chamfers into the "backside" to facilitate the starter pinion meshing. Pictures do not show how much wear in comparison to the teeth on the other side. Use a straightedge to judge and go from there. - cts

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Sun, Feb 15, 2026 12:15 AM
Ccafer
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Location: Rochester. NY
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The backside is undamaged. There is a shoulder on the back side of the gear that is not on the front. It matches a shoulder on the back side of the pulley, I would imagine, to set up a proper centerline distance between the two. That could probably be addressed by the correct thickness washers acting as shims. Then, cutting the chamfers for pinion engagement. Something to consider. Thanks, guys.

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Sun, Feb 15, 2026 12:44 AM
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