My 2008 4/4 was bought with 7000 miles on the clock. It had had one king pin replaced already.
I chose to replace both with hard chromed king pins soon after acquisition and wrapped the pins / springs in Chamoise leather gaiters held in place by cable ties to keep the grit and road grime out. I grease at approximately 500 mile intervals myself and KNOW THE JOB IS DONE. I have done another 37,000 miles since that time without any further trouble from the king pins.
I had a local engineering shop do the reaming, but I may invest in a reamimg tool and do the job myself next time. I believe the fit within the bronze bushes should be an easy push fit rather than a tight interference fit. Too tight and the steering takes too many miles to free up.
Your right about the fit Graham, should never be inference as that's far too tight. I set them the way I was taught and have demonstrated it to quite a few on this DG that I have done the job for ;-). Dry the pins should be free to fall through the bushes when held vertically but when coated in engine oil the pins should be able to support their own weight. I can assure you that takes some practice but it is possible, you also need a highly accurate adjustable reamer. Mine is a spiral fluted 3 element job with one spiral opposing the others, not cheap and cost in excess of £300 but it cuts like a knife through butter. As its adjustable I can get it resharpened and readjust it, I am told to lie down when told what a regrind will cost so I am using lots of cutting fluid and hoping ;-). If you want a drive up to Leicester I have a Hydraulic press as well ;-). Coffee if your lucky ;-).
