The upper image in the picture shows a new front shackle. The image below shows a severely worn usually caused by lack of regular greasing.

If your front shackles look anything like this then its time they were replaced. Unfortunately new shackles aren’t readily available but it is now possible to buy new pins to enable you to recondition your old ones.

The following instructions and photo sequence are intended to enable you to carry out this task.

Unscrew and remove the grease nipple. Inspect your pins to ensure that they are suitable for repair. Check that the surfaces on the side plates around the pin and hole are not badly worn. Light damage can be filed flat after the pin has been removed. Also check that the side plate is not twisted.

If it is badly worn or twisted discard it and use another one!

Hold the pin tightly in a vice and hacksaw of the worn pin. Cut as close as possible to the side plate without actually cutting it. Carefully remove the remains of the pin by filing. 

Using the small hole in the side plate as guide carefully drill through using a letter Q or 8.5 mm. Ensure that the side plate is flat on the drilling surface and that you drill squarely. Insert a 1/8” BSP tap into the existing thread in the grease nipple hole and tap a thread right through the side plate.

Take your new pin and drill a small hole, (1/16th-3/32nd is sufficient) from the point marked, into the hollow centre of the pin. This is to allow grease into the bushes.

Tightly screw the new pin into the side plate. It is advisable to use a thread locking compound on the thread to prevent any possibility of it unscrewing. (Loctite etc). After tightening ensure that the pin is square to the side plate and not “drunk” as shown in picture.

If you have done the job correctly and the pins are square then the two halves of the shackle should slide together without undue force. Fit grease nipples in the side plates. NB. The original nipples are too large for the new pins and will have to be replaced with smaller ones. Any decent engineering factor should be able to supply suitable ones.

G) Job done and you now have a reconditioned shackle!