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D2 4U Pony Clutch Starter Pinion Housing Removal

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4 years 4 months ago #217610 by dad59
Hi Have a D2 4U6974 I have removed pony motor but having trouble getting the pony clutch starter pinion housing off..have undone all bolts I can see and won't release have lubricated housing and hit it from all angles and not even budging is there something I missing as I don't have a manual. Any help would be greatly appreciated.. Cheers

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4 years 4 months ago #217613 by gemdozer
Replied by gemdozer on topic d2
You have to removed the 4 bolts from cluch housing and angaged the pinion and let the cluch lever on it it could help to turned the cluch housing and use some lubrifiant to make it more easy for removing.

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4 years 4 months ago #217614 by Deebo

You have to removed the 4 bolts from cluch housing and angaged the pinion and let the cluch lever on it it could help to turned the cluch housing and use some lubrifiant to make it more easy for removing.


I found the biggest cause of resistance to removal was the large o ring so a little heat to soften it made it much easier. Best to replace it anyway so didn’t do any harm.

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4 years 4 months ago #217617 by neil
They can be very difficult to remove and often things get damaged in the attempt. What I found, along with Deebo's recommendation to heat, is to try to get penetrating oil to that o-ring. They dry out and stick like glue, but once there is some lube in there, they will move. Still not easily though. The bore is likely rusted adding to the difficulty. For tooling, I've used blocks and a bar to apply good solid pressure to the end of the pinion shaft while wiggling the clutch body to and fro and keeping up the flow of lube. Resist the urge to put too much leverage against the mounting flange because it breaks easily - just some, and if you can have your helper lean on the aforementioned bar, then you can use a pair of screwdrivers or similar prying implements to wiggle against the flange.
When you reassemble, there is a different part # for an o-ring that is a little smaller in cross-section that will make reassembly much easier. Be sure to sand out the bore in the flywheel housing and liberally coat with anti-seize and some engine oil so your kids can remove it in 20 years' time.

Cheers,
Neil

Pittsford, NY

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4 years 3 months ago #218183 by dad59
Thanks for your help.. I will get onto that hopefully It will work for me will let you know how I go Cheers Matt

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4 years 3 months ago #218187 by oldbeek
If you can get into twist back and forth, the lube will get into the o-ring better and lap out some of the rust.

Cat 12 grader, 8T6995 running and restoring, Cat 12 grader 9K3585. parts machine, Adams leaning wheel Pull grader Mod # 22, ser#438

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