Scrambler250

Finally got all my ball joints in, and the lower right side moves freely in the end forging (inner knuckle). I've checked it against the old ball joint and both measure the same. Both will also slide in and out of the forging freely. The old one DEFINATELY was not moving before I took it out. I got the ball joints from quad4x4, so I'm gonna call him and see what the new ones are supposed to measure, but it looks like the problem is in the end forging. Any ideas on how to fix it? The only thing I know to do is to get a new end forging, cut the old one off, and weld the new one on. I'm a little nervous about welding a new forging on, because I would guess it has to be at exactly the right angle for everything to work. I've found a few D60 forgings for sale, but are all D60's the same forgings?

CTD NUT

No, there are many different knuckle carrier forgings for different D60 applications.......it seems fishy to me that the old balljoints were tight and the new ones are sloppy......do you have an old balljoint and some calipers?.......If you do, I would measure and compare for yourself.

Scrambler250

The old and new measure the same. The really weird thing is that the ball joints measure bigger (tenths of a mm) than the forging. I measured everything last night with a slide style caliper, I'm gonna try again with a digital to get more precise.