Installing CPP disc brake kit on DJM beams

[Garf]

Has anyone done this? Having trouble installing the seal / bushing / beam to spindle. Just not enough room. Wondering if there is a trick to it or maybe the bushing isn't pressed in far enough on the spindle causing the seal to stick out too far. Any help is appreciated.

[rhyne]

i did this a few years back and vaguely remember it being a tight fit. can you throw up a pic to show what you got maybe it’ll job my memory a bit.

[Garf]

This second image is the bushing without the grease seal, and the other shows the grease seal sticking out maybe 40 mils. Seems like the DJM beam would hit this seal and crush it if it's not fully seated into the spindle like the bushing is. And there doesn't seem to physically be enough room for the bearing, axle, and seal to fit the spindle on. Any help is appreciated.

[rhyne]

i may be off here but seems if that grease seal was flush inside the spindle it would serve no purpose. grease would come out between the beam and spindle. it has to seal the gap between the 2. the seal should fit inside the beam in the same manner then tap the bearing in. i do recall having to knock some paint off the beam ends and grooves to allow for fitment.

[Garf]

i may be off here but seems if that grease seal was flush inside the spindle it would serve no purpose. grease would come out between the beam and spindle. it has to seal the gap between the 2. the seal should fit inside the beam in the same manner then tap the bearing in. i do recall having to knock some paint off the beam ends and grooves to allow for fitment.

Thx. My thinking was the "seal" is between the rubber inner ring of the grease seal and the king pin. And if the grease seal is not fully inside the spindle where the bushing is, that it will get crushed by the axle and break off and fall out, leaving a lot of "play" for the axle to move up and down. I was thinking about removing some paint from the axle but the DJM beam measured the same as the OEM. I just ended up putting a small 0-ring over the kingpin that fit inside the spindle and everything fit perfectly. Not saying it's right, just what I did. Will keep an eye on it and grease it as needed.

[sargentrs]

The seal does fit flush with the spindle and yes, when you grease it some does squish out. The kit comes with shims and you are supposed to install them on top to take up the slack to like .005-.015 between the spindle and the I-beam. The grease that squeezes out also lubricates the surfaces between the spindle and the I-beam.