Bushing Issues..

[JohnJohnson]

I decided to rebuild the front axle on my m35a2, ordered a rebuild kit and front axle disc brake kit from boyce, got my new axle housing wobble seal in and installed new bushings from the boyce kit in my king pin caps, went to reinstall the knuckle and I couldnt get the caps on, found out the new bushings now no longer fit on the king pins on the axle, I got a small lathe so I cut them and ended up taking about .005 out of both top and bottom bushing just to get them to fit, I made the poor assumption that the bushing issue must be just with the king pin bushings (since they look like a piece of copper plumbing pipe) and went ahead and replaced my spindle bushing, now i cant even get the spindle back on, pulled the axle shaft back out and the spindle wont slide all the way onto the axle shaft, it stops dead right when it gets to the part of the axle shaft where the bushing rides, all these bushings fit before they were installed so Im thinking theres an issue with the outer diameter causing them to crush in the inner diameter when installed, I installed the bushing with bushing drivers, theres no signs of flaring on the lip or anything like that, do these bushings need to be reemed out after install or did I get out of spec junk? And just to throw it out there Im a diesel mechanic with 20+ years experience so I feel like this is a parts issue, havent messed with to many these rockwells so i figured Id check with you gurus before I try to order new bushings or track down someone with a bigger lathe, just wanted see if you have run into this issue before or am I just a goober, thanks

 

[cattlerepairman]

I know that one of mine fit like a glove, the other did not (and became a victim of my anger) and I subsequently learned that, yes, the bushings do need to be reamed to fit.
As they say...weird. But true.

Here is the thread I was thinking of:

Kingpin Bushings

I am in the process of rebuilding my front end, and found that the kingpin bushings are too small to fit over the kingpins. I double checked the part numbers, and everything is correct. Am I missing something???

www.steelsoldiers.com

Sent from my SM-G991W using Tapatalk

 

[gringeltaube]

yes, the bushings do need to be reamed to fit.

 

[JohnJohnson]

I figured as much, thank you for the info

 

[cattlerepairman]

I found the thread and updated my post above. It seems that a brake cylinder hone works well to increase the ID of the bushing.

 

[NY Tom]

That works or you can buy an adjustable hand reamer of the correct size.