Morning Caveman,

I have posted previously on the best way to fitit BRB's, If you pull my posts by searching sewin you should find them. DaveW has also done an in depth on this subject.

However, Richard has given an excellent account and is a man who has done the job too!
Just some clarification for safety though in case you want to rush out now and start!

The oiler bolt is the top mount for the spring assy. and before you remove it you will need to support the bottom of the hub/pillar with a jack. This has two benefits, the first being it prevents the whole suspension assy. from blowing undone as you are releasing the spring pressure by removing the oiler bolt and the second is that it will keep everything in line for reassembly... realigning the oiler bolt into the top of the pillar is a real pain and the very fine threads allow it to be cross threaded very easily, so hand engage only on refit and be sure its correctly in before using tools! When you remove the oiler bolt immediately insert a suitable screwdriver or punch into the hole as this will act as a safety device should things move and also help with realignment should there be some level of misalignment.

Your problems:

loosen the wing stay as Richard suggested, you will find you have some movement on the slotted hole, also nothing wrong with removing a corner of the stay should you need to, obviously keeping the patency of the structural hole though!

Why does your oiler bolt look out of line? Well it could be for a number of reasons and its a little hard to diagnose from a picture. Usually if it's cross threaded it's almost impossible to wind the whole bolt into the pillar. If you have the original fitment pillars, stainless, they are still fairly hard and if hard chrome have been fitted, well they are really tough! I'm afraid you will only find out when you strip things down. You will need A/F tools here not metric!

The BRB's themselves; good quality options have a welded washer which fits to the oiler bolt end. When I fit them I prepare the outer edge of this end by rounding it off from its square profile following the profile of the washer... DO NOT grind away any of the welded area. when done remove the screwdriver and install the top of the BRB and hand tighten the oiler bolt. Now approximate the chassis end onto the outer return lip of the chassis. push it against the vertical element and mark the chassis line onto the BRB. You will be relieving some of this inboard square edge in order that the hole when drilled into the chassis flange is closer to the vertical chassis element. This prevents weakening the flange which forms the structural strength of the chassis. Don' drill it yet! Now with it all assembled and safe, refit the wheel and check for clearance of the tyre hitting the BRB on full lock. On a wide bodied car this is unnecessary but a narrow bodied 4/4 with taller profile tyres it can be an issue. If this is so PM me as we will have to have an in depth conversation! When you are happy with fit and function its time to drill the chassis. It will need drilling from underneath so clearance is required under the car and my post does explain how to transfer the marked point for drilling from the top to the bottom of the chassis.

Most BRB sets come with fixing bolts, They used to be supplied with shear bolts so that in the event of a front collision the rear bolt would shear minimising chassis damage to that vulnerable flange but I see they now seem to come with high tensile steel options. I'm not happy with that and have been running my plus 4 with 6mm brass bolts and stainless nyloc nuts. I check them every year but they show no signs of deterioration but I change them out anyway in case of fatigue I can't see. Each to their own I suppose!

When you start to crack open the fittings just make sure you leave them still tight then install the holding jack, lift it directly under the hub at the pillar and lift carefully until you just see the outer axle tube of the cross head move vertically and stop. this will position the pillar and secure the suspension for you to carry out the task. Good luck. Its a relatively simple job but you do have to understand the method and how to keep yourself safe.