on my D4-7U you don't have to
What's the trick?
You should have to lift the pony motor up about 2" to get the pinion out. The gear that drives the pinion assembly from the pony motor is in constant mesh. So it needs to lift the pony to make clearance. Make sure to latch the pinion it makes it a little easier to get the pinion assembly out. You may have to take the back off of the governor housing. To get enough clearance. They are a tight fit on my D2.
Yes, they tell you that in the manual but the gasket usually gets tore up in the process. Better to remove and re gasket all in one shot than having to go back later and fix the water leak. Some have good luck with greasing the gasket for the next time.