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TR4/4A TR4A Front Suspension

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KVH

KVH

Obi Wan
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I have to replace a trunnion. That little bottom "coin" is being somehow pressed out from age or wear.

My manual describes the reassembly procedure for the ball joint, control arm bushings, caliper, etc. and then says to "offer up" the hub and vertical link assembly to the spring tower and to secure the upper fulcrum.

I realize there may be numerous ways to rebuild the front end, but is that what most folks do--assemble the parts, then swing the unit up, rotating on the lower bushings, and securing the fulcrum.

I think the last time I did this, I put the upper control arms in place first, then swung the unit between the arms and fastened at the ball joint. No wonder I pondered how one might torque those castle nuts in a 1/2 inch space.

I'd be interested what others do--and how much grease to cram into the trunnion. thx
 
https://www.74tr6.com/6-tech.htm

I really like these SixTech manuals that Brosky and BobbyD put online. The front suspension section was really helpful when I went through my rebuild. I think he even discusses the different ways of accessing different components.

I had to get to the trunnion bolt (forgot to grease it during the tech session) and used a floor jack to stabilize everything. I don't know how you could do that if you let the lower a-arms and the spring down to get the access to the trunnion, but I guess you could pull the upper section up and out to get to the trunnion.

I'm squirrelly and would take the long way around (remove shock, compress spring, and then disassemble where I needed) just to make sure I could move as slowly and deliberately as possible. That is why I would go broke as a mechanic.
 
Hi there - just finished with this.

Put the cap back on the bottom of the trunnion when it is separated from the link BEFORE reassembling anything. The replacement caps I got from Moss did not fit, not even close, so you may want to ask around as to recommendations there.

Trunnion is supposed to be 1/4 to 1/3 filled with gear oil before being reassembled.

I'd suggest ordering new seals for the top of the trunnion as well, chances are the existing ones are old and will leak.
 
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