Pic heavy. I'll make a comment above the images. Final hindsight comments below.
8mmx1.25 Bottom Thread Tap
1/4-28 Start Thread Tap
7/64 drill bit (pilot hole)
13/64 drill bit (tap hole)
8mmx1.25 Grub/set screw 1/2 long or equivalent
1/4-28 grease fitting
machine screw to remove cap
I had a vice and a center punch and some other niceties. You can do it without them.
Here is a pic of the groove added for the lower bushing. In recent discussions this may not be necessary. I feel better with it and it was free. If you have to pay a shop to do it, weigh the cost/reward. The groove is 360 degrees 1 1/8 long.
First I removed the factory plug. I took a punch and added a hole. I inserted a machine screw and pulled out the screw with some vice grips. The cap is not hard to remove.
Once the plug is removed you'll see the factory hole steps down from the approx. 8mm opening to a 7mm-1/4inch opening. You can also see the "peanut butter" factory grease (yellow pic).
Once the cap was removed I threaded the larger 8mm opening for a grub screw. I loaded the threader with grease to capture as much metal as possible. Since the opening gets smaller I used a bottom tap.
From there I went to the jeep to see the best location for the new grease fitting. I decided a little left of the LDI label between the oil filter and the motor mount.
I started with a 7/64 pilot hole and went to a 13/64 tap hole for a 1/4-28 fitting.
Without drilling the bushing I install the grub screw in the factory hole and the grease fitting in the new hole to see if I could determine where the grease would normally come out. NO SUCCESS. If there is a way I couldn't find it. I tried high pressure air with no success either.
Finally I drilled the bushing using the same 7/64 bit I used for the pilot hole. Drilling the bushing was easy. I added grease to the drill bit to catch shavings (this in not
the actual size drill bit for the bushing. It is meant to show the greased bit and metal shavings). I drilled the bushing through the factory hole.
Here is the final project. The white is thread sealant. The grub screw has red hydraulic locktite.
1. I should have installed the grease fitting a little lower to help the grease gun fit on the fitting without interfering with the sensor head. It fits, buts it's close.
2. I may change the fitting to a recessed fitting and use a needle. I don't know if I like the extended fitting.
3. Remember the housing is aluminum so be extremely careful not to over-tighten the fitting or screw. The threads can easily stripe. Tight enough is all you need. This is why I think I'll go with a recessed zerk and needle.
4. When drilling through the housing, you will feel the drill bit bottom out. Don't worry about drilling too far. I was concerned when drilling the new grease fitting hole that I would accidentally drill through the bushing. Not an issue at all.
5. When cleaning the metal shavings out make sure to cover the sensor. It is magnetic and I have a bunch of shavings to clean off.