Fixed two issues with D2 pony pinion

All,

Yesterday I fixed two issues with the pony pinion on one of my D2's. I thought I would share in case it helps someone when they run into this. The issue was two fold, but related. I was having trouble getting the pinion engagement lever to get the pinion latches to snap in fully. The lever would get it most of the way, but I had to reach in with a pry bar to get it the last little bit. So, here is how it all went down. This past spring I pulled the pony to fix broken parts in the pony clutch. One problem I found was that the keyway was chewed up on the shaft that the engagement lever slides onto. The keyway was un-useable unless I was to weld it up and remachine. So, instead I crossdrilled a hole through the engagement lever and shaft. I then put a 1/4 bolt through both of them. Unfortunately, I must not have got the hole in exactly right spot because the lever ran out of travel before the pinion latches snapped in. I should have checked it before I drilled the hole. So, yesterday I took the bolt out and rotated the lever into the correct position (I wasn't off by much). I then put a 1/4" carbide burr in my die grinder and reamed the hole out to re-align it. Then I used a 5/16" drill and opened it up for a 5/16" bolt. Now the lever is in a much better location.

I'm not entirely sure what caused the second issue. Once I got the lever travel correct the mechanism that pushes on the end of the pinion sleeve ran out of travel before the latches snapped in. It was about 1/8" short or so. The sliding arm that pushes the pinion sleeve wasn't able to slide any further for whatever reason. I really didn't want to pull the pony again to figure it out. It took me a while, but I finally figured out an easy fix. I fired up the lathe and turned a small button that I could press onto the little nub that sticks out of the end of the pinion sleeve. I gained somewhere around 1/4" with that piece. So now the engagement arm that pushes on the pinion sleeve has plenty of travel to get it to latch in.

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well, there doesn't seem to be a delete button, so this is the best I could do to remove a double post:confused2:

NICE! I guess the old adage "measure twice......drill once" still applies!