Well crap I just typed a bunch of stuff in here and bingo it all disappeared. So here goes again.

Not to be a pest but still not sure you have the correct spring. If you go to all the work reworking the pinion it will be a shame if it still cannot be adjusted because of the wrong spring. The 6B1909 is used in many pinions and is 2-1/16 long not 2-1/2. Did Cat sell you a 6B1909 or some other replacement number? The wire sizes look different in the two springs pictured in above post. The 6B1909 wire diameter is .071 when measuring the new one I have.

Just my 2 cents.

Jim - the photo shows my original and the first one I bought (from Florin). The one I bought from Cat is not pictured, but is similar size as the smaller one in the photo. It is a 6B1909 and in the Cat package like the one in your picture.

"Cat wrote:

Jim - the photo shows my original and the first one I bought (from Florin). The one I bought from Cat is not pictured, but is similar size as the smaller one in the photo. It is a 6B1909 and in the Cat package like the one in your picture.

Great! That is the correct spring! I thought you were maybe putting in spring that would cause you nothing but grief. Those little ponies are great as long as the latches work properly, otherwise they can be quite a headache. Best of luck!