Front suspension rebuild

The Sprite failed the annual test (APK in Dutch). To much play in the fulcrum pin in the lower wishbone and in the kingpin lower bushing.

Worn Fulcrum pin
Worn Fulcrum pin

Bad maintenance by the previous owner and old hardened grease caused wear on the Fulcrum pin and bushing.

Worn Kingpin and lower Wishbone
Worn Kingpin and lower Wishbone

The kork seals are worn out and the Kingpin shows wear. You can even see the grease groove from the bushing.

Old and new fulcrum pin
Old and new fulcrum pin

Old fulcrum pin next to a new one

Painted spring seats
Painted spring seats
Reaming lower bushing in stub axle
Reaming lower bushing in stub axle

Only the lower bushing need to be replaced. To get a nice fit the bushing has to be reamed to the diameter of the Kingpin. I used a lathe to align the reamer with the bushing and rotated the reamer by hand.

Fresh assembled Stub Axle & Trunnion
Fresh assembled Stub Axle & Trunnion
Lower wishbone with cork seals
new cork seals, kingpin an lower wishbone
Dust tube with spring in Stub Axle
Dust tube with spring in Stub Axle
Long bolts for mounting spring
Long bolts for mounting spring

Using two long wire-ends to compress the spring.

Left front suspension
Left front suspension

Finished assembly, unfortunately I rotated the trunnion top 180 degrees, which caused a total misalignment (too much toe-in )of the wheels.

Trunnion mounted backwards
Mistake, Trunnion mounted backwards