D2 Starting Gear

Foster. .I hope someone else on here can help diagnose the problem. What it almost sounds like to me is the button on the end of the pinion is worn and not allowing full engagement to start with.To tear into it can/may be a pain. If. .IF you're lucky, you can possibly pull the pinion/ clutch control from the bell housing without taking anything further apart but that may depend on which model you have. I just went out and looked at my 5J and it looks like to get the pinion/ clutch out, I'd have to pull the injector pump first to get the needed room to slide it forward far enough to take it out. Either that or pull the engine and work in it while it's still in the bell housing. But then, I'm not familiar with all models of the D2 so there may be easier ways. I"m sure someone else on this board can offer more help.

Good luck,
Paul

Foster,
On my D2 mine it was not unlatching it was not engaging. I couldn't lift up the lever it was stuck or jammed. After doing everything I could think of I had to take out the pinion /clutch out. What happened was the bolts that hold in the sleeve assy. on to the end of the shaft fell out and the sleeve was loose on the shaft. When I took the pinion/ clutch out the sleeve fell into the flywheel housing. What a bear to get it out I could bearly reach it. I'm no pro at Cat's but I am a wrench. I don't know if thats your problem. But to take the pinion/ clutch out you have to lift the pony up a few inches (fun fun fun) take the cover off the end of the pump. I got a rebuilt pinion/ clutch assy. ( I guess thats what you call it) and it works great.
Now I'm just waiting for the next thing to brake !!!!!!!!

Good luck !!!

To pull the pinion assy out, you will need to remove the governor housing from the injectoe pump. Once that is removed, remove the four bolts holding the pinion assy to the flywheel housing, then pry/push/pull/wiggle the pinion assy off. There is an o-ring sealing it to the housing, and if you are too rough with the assy, I have seen the engagement end of the housing crack or break at the "cut-out". Once out, you will be able to fix your problem. Parts are still avail., but the cast piece that holds the latches is $$$. Good Luck!

By "unlatching" do you mean it disengages to soon or will not engage????

Most common source of problem is a bent pinion engagement arm (from holding/forcing pinion to stay engaged) Check end clearance, should only be about 1/8 in or so.

The manuals don't show anything on removal of engagement arm assembly but it is retained by the engagement lever and shaft.

To remove clutch/pinion engagement assembly you do not have to remove governor or pump.......just the back cover of the governor.....also remove the engine cover bolt closest to the assembly. Pinion needs to be engaged to shorten overall length for removal. Also remove the pony motor and reseal. The raise one end is a joke.

The other most common problem I have found is that the "stop" that the latches engage is not always indexed properly so the latches never have a chance of engaging correctly for very long.

Ah HAH. .I kind'a figgered there might be an easier way to skin that particular cat! Engaging the clutch to shorten the overall length makes sense. .I hadn't thought of that earlier.
Hope you find the problem and "get 'er done"

By "unlatching" do you mean it disengages to soon or will not engage????

Most common source of problem is a bent pinion engagement arm (from holding/forcing pinion to stay engaged) Check end clearance, should only be about 1/8 in or so.

The manuals don't show anything on removal of engagement arm assembly but it is retained by the engagement lever and shaft.

To remove clutch/pinion engagement assembly you do not have to remove governor or pump.......just the back cover of the governor.....also remove the engine cover bolt closest to the assembly. Pinion needs to be engaged to shorten overall length for removal. Also remove the pony motor and reseal. The raise one end is a joke.

The other most common problem I have found is that the "stop" that the latches engage is not always indexed properly so the latches never have a chance of engaging correctly for very long.