OK, FINALLY DONE !
The new pins received from AB and were pressed in today. Dry fitted the end caps into housing and smooth fit.
Came home and finished. New roller bearings, washers, spring washer and caps. Greased up, and slid right into the housngs !
First set must have been a bad bathch from the supplier. Not only were the pins approx. 2mm too long, but too snug in diameter as well. Roller bearings were way too snug.
All fixed now. Smooth fit and operation.
Thank God it's winter and it was a basement project not a garage nightmare.
Thanks to you all here for the advise and support.
Clay
PS: a good machine shop guy is invaluable to this process. Good thing I found one.
Rob Vitalteti
Thunder Performance
Millord Connecticut.
203-877-9189