Is it possible to install steering knuckle bushings without removing the steering knuckle? FSM calls removing it but like some other repairs there are sometimes easier ways than the FSM procedure.

If you are asking about the bushing inside the spindle, no you do not have to take the knuckle off. You do have to remove the half-shaft. If you plan on staying IFS I would replace them with the roller bearings instead of the brass bushings. If you use the brass you may have to hone them out a bit to get the half-shaft to fit. On my SA I used a brake cylinder hone, light oil like 3-in-1 and an electric drill. Either way you go put them in the freezer for 24-hours before you do the install.

Yes. the spindle bushings. On net search I see in two articles that say 89 and up only on the roller bearings. Like you are suggesting, I thought that the spindles 89-early 09's were the same for the 86-88's. But doesn't installing the bearing require a press? ...so spindle would need to come off? I have never removed the half-shafts on this truck and I need to change out the lower ball joints anyway... do you think it would be easier to pull the spindle off and not have to remove the axle?

Both the roller and the brass bushing need to be pressed in. From what I have been told the roller bearings will work in the early spindles, this was by someone who had done it.

You can make a simple press out of a socket with just about the same O.D. as the bearing/bushing, a large washer that is bigger then the hole in the back of the spindle, and a long ½-inch bolt.

Put the large washer on the bolt. Slide the bolt through the spindle from the backside. Start the bearing/bushing into the front side of the spindle. Slip the socket over the bolt with the ratchet side out. Put a flat washer on the bolt against the socket and thread the nut on. Tighten the nut up until the socket is snug to the bearing/bushing. Make sure the bearing/bushing is going into the spindle straight. Slowly tighten the nut pushing the bearing/bushing into the spindle.

David, Have you or anyone you know pressed (pulled) in these particular bushings using the bolt/washer method? The reason I ask is that I got my 'spare parts' spindles out just to make sure I could get the outer one out without a puller and these things are really really tight in there...
Don't want to get the truck in and apart to and pull the old ones out to find I can't get the new ones in without taking the spindles out.

No. I did not have my IFS long enough to have thing go wrong with it.

Unless your bushings are really worn out and sloppy you can make or buy a spindle lubricator tool. This will take care of most noises. More info:

http://www.yotatech.com/f116/spindle-lubricator-ifs-axle-shaft-pictures-100327/

Yup. I made the tool a while back. Works great. My bushings are really shot. They need replacement definitely. I'm trying to find out if new ones can be installed without pulling off the spindle.

Since you have spare spindles and you want to change the lower ball joints anyway, why not just swap them out? If you have spare axles as well, you can use the axles to check the clearances on the spare spindle's bushings. Those bushings are usually trouble free unless they've been through a lot of axle-deep mud. I'd just swap them and use your lube tool on them.

I'm not trying to steal the thread, but do the roller bearings fit the solid axle as well? <img src="/forums/images/graemlins/smile.gif" alt="" />