Starter Bushing (SB0) not taking up enough slack in TRE? (1 Viewer)

[RWBeringer4x4]

Hey all,

Just reinstalled my tie rod tonight after converting my 75 FJ40 to FJ60 knuckles.

I pressed starter bushings (part number SB0) into the FJ60 steering arms to make them work with the FJ40 tie rod ends.

However, it looks like they didn't cut it - fully tightened, the hole for the cotter pin still sits well above the castlations on the castle nut...same on both sides...

Sorry for the dark pictures:

Is this normal? What are my options? I'd like to avoid running a washer on top of the steering arm, but I've seen that done...


Also - looks like the boot on one end is damaged from a bad alignment or a backspacing issue on the wheel:

As you can see, it's bleeding grease. Are replacement boots available for these? (555 TREs from Kurt)

 

[Poser]

SOR sells the machined spacers for the arms and poly boots...

 

[RWBeringer4x4]

SOR sells the machined spacers for the arms and poly boots...

I knew about the spacers - was hoping to get away with a $3 starter bushing instead of a $20 spacer...Didn't know about the boots though - I'll have to look into it. Do other vendors carry boots as well? I'll ask around...SOR has some hard to find pieces but last time I ordered something from them, the shipping was astronomical.

 

[RWBeringer4x4]

On that note, if these bushings are SUPPOSED to get the job done, is there something else going on here, or have these always been a so/so fit?