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Old 21-04-2015   #31
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Re: Kingpin renewal

Just thought I would update this post with a series of photos showing the process for fitting new kingpins.
Its not a job for the novice, its not actually a nice job at all.
So if you can afford it, go for the replacement or exchange units and save yourself a whole load of hassle.
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Old 21-04-2015   #32
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Re: Kingpin renewal

This is my next job Sean. Well stripping them and blasting them at least. Buying new you don't get the satisfaction as you do when you take old ones and make them new. Good job
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Old 21-04-2015   #33
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Re: Kingpin renewal

Quote Originally Posted by Paolo66 View Post
This is my next job Sean. Well stripping them and blasting them at least. Buying new you don't get the satisfaction as you do when you take old ones and make them new. Good job
But, you get the satisfaction of knowing you didn't have to do it.

cheers, Steve
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Old 21-04-2015   #34
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Re: Kingpin renewal

You don't get the benefit of a throbbing, swollen thump, cuts all over your left hand hand ingrained filth that takes weeks to wear off either.
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Old 21-04-2015   #35
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Re: Kingpin renewal

I'm in the throws of doing this now. I looked to buy replacement units but most everyone seems to be out of stock and have been for awhile or their prices are really high.

Next step is to push out the old bushings. Sean, I know you made your own drift pin on the lathe. I'll scrounge around for something similar. Did you heat up the bushing at all to help drive it out?

I like how your caps were threaded on. Mine were spot welded so, I'm guessing I'll have to do the same when I get to that point.
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Old 22-04-2015   #36
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Re: Kingpin renewal

The bronze bush is very thin, you can get them out with a drift but you will more than likely damage the bore of the hub. The drift needs to be a good fit inside the bush and then it should tap out quite easily.
Getting them back in also requires a similar tool which fits inside the bush, but with a hole in the middle so you can use a nut and bolt and draw the bush in. If you try tapping it in you will damage the bush.
I haven't come across anyone else with the screw in type cover.
The standard one seems to be just a domed cap which you place in the hole when completed and hit it with a drift/hammer and it will then expand and seal up the hole.
I will probably have to do this on my 500D model I guess.
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Old 22-04-2015   #37
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Re: Kingpin renewal

The bottom cover is just like a core-plug and sits up against a ledge at the bottom of the hub-carrier (no, I have never seen a threaded 1 either). The best way is to drill a fairly large hole in the plug prior to knocking it out with the gudgeon-pin. This allows it to distort and come out without doing any damage. The new cover will be fairly heavily 'domed' to allow it to be put in place--hit the centre of firmly it with a wide drift to flatten it out, tension will then hold it in place. I would recommend that a long adjustable reamer is used, after the new bushes are fitted, to align them and obtain the correct clearance---but beware, the difference between 'just right' and 'loose' is very small!
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Old 22-04-2015   #38
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Re: Kingpin renewal

I've tried to find a proper Fiat reamer in the internet; I am prepared that it might cost the earth. The part number seems to match to some extent with a 16mm Dormer reamer.
I wonder, does anyone know of a source for the correct reamer or a non-adjustable one of the right length?
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Old 22-04-2015   #39
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Re: Kingpin renewal

Quote Originally Posted by fiat500 View Post
I've tried to find a proper Fiat reamer in the internet; I am prepared that it might cost the earth. The part number seems to match to some extent with a 16mm Dormer reamer.
I wonder, does anyone know of a source for the correct reamer or a non-adjustable one of the right length?
Going by your post, you already know the part no., so just in case it's useful here are the part numbers I could find fir Fiat kingpin tools...
74056 Remover and installer, knuckle pillar and leaf spring bonded rubber bushings
74106 Remover and installer, knuckle pillar bushings
90316 Reamer, knuckle pillar bushings

cheers, Steve
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Old 24-04-2015   #40
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Re: Kingpin renewal

Just done this little job, well stripped them anyway. As long as you have the correct drifts you're fine. I work in engineering so was able to jump on a lathe and make my own. If you can't get access to the drifts I would consider just buying reconditioned ones.
Sean - my bottom cap was also screwed in. When fitting the new kit do you have to buy a screw in one or do the domed caps fit to the threads?
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Old 24-04-2015   #41
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Re: Kingpin renewal

There are a couple of kits available, but the only ones i have seen come with the domed cap. I reused my screw in covers. Not sure if you can use the domed caps if your ones are no good.
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Old 24-04-2015   #42
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Re: Kingpin renewal

With all this talk of reamers thought I would mention that the measurement you need is 15.2-15.4mm with the kingpin being nominally 15.1mm. You don't want to exceed a 0.2mm clearance. A 19/32" reamer will do the job or an adjustable one. The clearance you should be aiming for is 0.016-0.02mm
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Old 24-04-2015   #43
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Re: Kingpin renewal

Damian,
we didnt actually use a reamer.
The bushes were a really good clearance fit on the shaft (with a little wet and dry paper). However we found the OD of the bushes were too much of a compression fit so machined them down to a fine compression fit. This probably stopped the ID from becoming too tight when inserted and therefore reduced the need for a reamer. You could actually machine them to be a clearance fit and then loc-tite them in.
The biggest problem was fitting the washers. If the washers have caused a slight recess in the hub then this needs to be machined/ground flat as it can cause problems inserting the lower washer which needs to be ground down to a good but not loose fit. Just enough clearance to be able to move.
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Old 26-04-2015   #44
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Re: Kingpin renewal

Similar to my experience as the pins on mine were very grooved and corroded and simply fitting new ones in the old bushes got me through the MOT. I doubt that will last as the pattern parts designer had given no thought to greasing properly.
What we need is to get Nev back on the forum, the original poster who has all the factory kit for the job.
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Old 27-04-2015   #45
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Re: Kingpin renewal

I was thinking of instead of using the copper bushes that come in the kit I could use some oil lite bushes. These are copper/bronze that are slightly porous. You leave them to soak in oil overnight and the oil embeds itself within the bush. They should provide better friction and lubrication properties. I'll post some photos when I get round to it
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