Willydigger, what happened with your idea of extending the opening in post 1037 on page 70?
The machine shop still has my OPDA. I don't want to rush them because they doing it for free. The initial plan was to use the existing stock grease fill location and add some tubing or some other method to move the zerk to a more accessible location. Since then FOG had mentioned drilling a hole in the front (easier access) area of the OPDA, below the LDI text in the LDI label. I am still waiting for the machine shop to finish the OPDA. It may be overkill, but cutting in the oil groove in the lower bushing is something I wanted to add.
Now that I've seen the side wall opposite of the stock grease location I am relieved to see how much metal is there. Aluminum is soft and I was weary of adding a zerk to a flimsy wall. I thought the grease reservoir was larger. I'll mock up some of the new pics tonight and repost my plan.
Willy, you could use the existing grease port and simply run a small tube to a remote/ more accessible location for the zerk which could be mounted on a bracket.
Six in one/half a dozen in the other. I still want to drill into the bushing since the stock grease port is suspected as a fail point. I would have to drill and tap the stock port and do the work of installing a tube, etc. Drilling and tapping the front seems simpler. Seeing how thick the wall is adds some reassurance.
The existing port has a press in plug. There is a pic somewhere in this thread. Once we discover a workable solution (meaning pics and step-by-step instructions) we should have a write-up thread separate from this thread.
Following the great advice from Willydigger, BigBob, Fog etc...I took on adding a zerk to the upper bushing area. However, even with Willydiggers nice color drawing of the assembly and zerk location, I still had a hard time visualizing the 2nd hole and purpose (180 degrees from the factory plug). In particular, only drilling through the "outer wall." So I cut my old OPDA upper bushing in half so I could get a good visual. So in case anyone else is a visual person like myself, I added some pics. Please ignore the vertical cuts in the inner bushing.
What is the seal made from? Metal, plastic, rubber? Do you have a pic? Was there any noticeable gap between the seal and upper bushing? Was there any grease/lube in the reservoir?
The seal is metal with a rubber seat similar to that of an inner axle seal. My resevoir had some nasty yellow paste that seemed to be very dry, almost like pie dough. I did exaclty what BigBob did as practice on my old unit...I drilled out the factory plug and then a small hole through bushing itself and then drilled/tapped 180 degrees on the other side but only through the outer wall.
When I hit the zerk with the grease gun, it flushed out the old yellow grease through the factory plug hole.
I will try to get some pics of the bottom bushing/seal area since that area is still in question.
1. Red oval--Yes that is a slit from the cut off wheel--that would be the solid bushing.
2. Green oval--Don't know exactly, I added more pictures that might help.
3. Pink--Yes that would be the path to the shaft itself from the factory plug to the small hole in bushing.
I added a couple more pictures here...I tried to show a cross section of the upper bushing assembly. I am still trying to figure out exactly how much of a gap there is between the seal and the bottom of the bushing. Since the shaft has that play in it (up and down), it is hard to estimate where everything actually seats.
Thanks Fog. One last question (I hope). You initially put the ZERK at the factory plug location, and then moved it around the housing. I am going to drill the hole for the ZERK in your second location. Is there a need to remove the factory plug and install a grub screw there, or can I leave it alone? I guess what I'm getting at is will grease pumped in at the ZERK dislodge the factory plug?
Thanks again for all your work and research on this deal.