I replaced ball joints on the '03 last summer or maybe not even that long and the steering started getting funky characteristics like before I replaced them the first time. The lower grease cover was no longer sealed and started deteriorating. I got into last night and the joint was loose and I replaced it, put the same top unit back in as it still looks new.

I put the spindle back on and started tightening the 2 nuts and before I could even torque them down good I noticed the spindle would no longer rotate. I pulled it back off and the holding rings for the grease covers fell off because the spindle had moved so high up the tapered bore that it squeezed them most of the way up. Nothing appears to be excessively worn but it seems that the taper should be grabbing the ball joint studs much further down and not allowing that spindle to come up so high. I even tried experimenting with the tension collet on the very bottom to get any adjustability out of the assembly but I didn't get any help from that part either.

I'm now wondering if the fix could be simple as replacing the old tension collet with a new unit or if the entire spindle needs replacing because the tapered bores are no longer at factory spec. There is no information on a resolution to this problem. I did find more than a few threads discussing the same problem "replaced ball joints and now the spindle won't move" but all of the posters solution was to back off on the 2 ball joint nuts until the spindle was free to move again.


https://discoweb.org/forums/showthread.php?t=92854


I know that any garage or mechanic would either do the same thing OR replace the 2 ball joints and the spindle with all new, genuine parts. I do have a set of genuine ball joints that I got on EBay and they fit the spindle bores the same way; the spindle still comes up too high before the taper is catching. I would rather take what I have and make it work so if any of you guys long in the Discovery game have come across this issue and sorted it out with a) new tension collet or b) good, used spindle instead of loosening the nuts and bolting everything else back on with yours fingers crossed, I would like to hear from you.

I only planned on this being a Sunday afternoon job but here I am borrowing someone else's car with my truck sticking halfway out of my grandmothers garage 1-hour away with no way to close the door or move the truck, I'm not the only one in frustration, unfortunately. And the "maintenance" light is flashing on the borrowed car so things are really just getting worse and worse.

 

until anybody says different, I'm going to assume that its the spindle bore/taper that has exceeded spec. I hate to throw money at the problem but all that i can think to do is go look at this other spindle for sale on Ebay. I have the factory Lemforder ball-joints so i can size them up with the bores on the 2nd spindle.

 

Replaced the spindle with a recycled version, went back together as it should, I assume, and is back on the road. Changed engine oil, made sure front axle fluid is full and now I just need to order that stainless steel flexi-hose to polish off the thermostat mod/ bypass delete.

 

Crazy, do you have a pic of the old one? Was the out of specness obvious?