D2 starting pinion removal

[ozcat]

G'day all, If Ozdozer or Oldmagnet or some of you highly experienced guys can tell me if I can get the D2 starter pinion out of my D2-5U if I remove the governor housing cover ? There seems to be no other way to get it out from my attempts so far.
The pinion throws out to early once I load the pony with diesel compression.
My D2 came from Perth and has damaged pinion latches that I could see thru the little inspection hole near the left foot po'sn. So no choice but to go thru the whole pony lift etc.
Thanks, Christopher
5U-17494

[SJ]

You know I can,t just remember on the D2 but the D4 "U" models all you needed to do is remove the gov. cover but I,m thinking just removal of the cover will let the D2 come out too. I guess the only thing to do is try it and if the gov. needs removing it,s not that big of a deal.If you take the whole injection housing off it can only go back one way with the off set drive so you can,t get it out of time by removing it.

[ozcat]

Thanks SJ. I have a D4 manual and it looks ot me like the D4 has more room than the 2 and thats what lulled me into thinking it would be a "straight out" job. Not so far. So will take the governor cover off tomorrow and wrestle with it some more and if that fails will take the whole deal off. Am surprised Cat made this job so nasty ie. remove all the gear around the pony, struggle with all the pony bolts, lift the pony blah blah..Anyway, will let you know how it goes in a day or so. Regards, Chris.

[OzDozer]

Gee, I don't know, Chris - you obviously aren't the right type of person .. with the 3½' long arms, with 3 elbows and eight fingers, that the D2 was designed for .. .. those blokes in the white lab coats make it look like a walk in the park ..

Yeah, the same gorillas who designed the D4, did precisely the same engineering on the D2 .. and the starter pinion is SUPPOSED to come out with just a little bit of jigging and wriggling .. after you've removed the governor cover .. .. however, they forgot to mention the missing skin and jammed fingers .. and the rust holding everything together, tighter than any factory fit ..

The bottom line is .. if the removal of the governor cover still doesn't help you get it out .. there's not a lot holding the entire fuel injection pump on .. apart from that one rotten bolt at the middle back, that gives everyone grief ..

Here's the scans from the book .. there's a couple of tricks involved, such as engaging the clutch pinion before you start to remove the assembly .. and removing one of the bolts from the side inspection cover ..

[AndyD2NZ]

Hi Ozcat , you should be able to get the sod out just by removing the end plate on the clutch ,a tight fit but it will come, the O'Ring can be stuck with rust and can be a pain, the D4's you sometimes have to remove the plate on the governor (some times) but I haven't had to on D2's cheers Andy

[8C 361]

My D2 came from Perth and has damaged pinion latches that I could see thru the little inspection hole near the left foot po'sn. So no choice but to go thru the whole pony lift etc.
Thanks, Christopher
5U-17494

Years ago I changed out all those parts through the clutch cover and inspection hole. I am not saying I recommend it but it can be done.

Tom

[compressor]

OZCAT,
Yes you can slip that little puppy just past the housing with the cover removed.
Done it 3 times.It still however a tight fit.Oz is right, your prob going to see alittle blood,and use so words you told your kid not to use,but that's o.k.
Also,be prepared to fish out the little short bolts that come loose from the pinion 14 years ago.They will be at the bottom of the case.
GOOD LUCK COMPRESSOR

[ozcat]

G'day All from Australia ,
Got the job done but only with the help from you guys. Much appreciated. In the end I had to take the governor off which wasn't too bad as that pinion would not get past the housing and missed out by maybe only 1mm ! ugh. But it was a good learning experience and all that is left to do is clean the faces for the Pony base gasket and lower that back down.

Somebody or something had seriously damaged the end off the pinion latches, pins and screws. One screw wasn't even there ! So all new parts that end and adjusted to 3 turns in on both and hope the Pony throws out early rather than later.

Should fire it up in a couple of days :-)

Thanks again to all who contributed.

Regards, Chris