So it turns out that both of mine are leaking grease, despite me trying very hard to seal them when i did the kingpins. I used a file to smooth away any rough edges, made sure everything was clean as a whistle and gave the plugs a good belt to seat and expand them, but apparently to no avail.

Can anyone give me some hints on getting them to seat properly? They're only a couple of quid from ecas so i dont mind buying another pair and having a go, I just don't think i could do a more careful job than i did last time...

Did you get the top of the king pin levelled with the top bush? If too high, the grease cap can't fatten and seal properly?

Yeah, it was all neat and level. The plugs even seemed to be nicely sealed when I did them, but after maybe 1000/1500 miles they've now started leaking at the top.

Mine failed first time, 2nd time was a charm despite the seats looking like that have been chiselled from the living steel rather than machined.

Of course the second time I smacked 'em good and hard from the start rather than build up and give the plugs a chance to work harden.

I also choose the softest grease, keep the gun in the airing cupboard overnight and warm up the pins with a hot air gun and take it very easy pumping the grease in.

What tool did you use to peen over the edge?

a pin punch ( flat point -not a sharp point center punch) on the cap just beside where the worm is coming out - so that the softer steel of the plug expands into the tiny gap in the housing thats letting the grease out.

if its more than a worm then the top plug isnt fitted properly - from new i clean up the housing of old peening, dish the plug further by placing it in an old socket and belting it. Seat the plug by using the same socket so that the circumferance of the plug is getting pushed down, not the centre - once its seated one of the KP drifts used to flatten the plug and expand it into the housing - with a couple of punches to the cap to seal off any local worms

Martin, I use a centre punch adjacent to the worms to expand the plug slightly in that direction. Seems to work in the many pin changes that I've done.

Rgrds
C