Attention: TDR Forum Junkies 
Since DC's adoption of the "greased for life" balljoints and other suspension components, we have steadily seen a stream of reports as to early wear and failure of these components. While in theory, a PROPERLY manufactured and lubed component MIGHT deliver decent operational lifespan, the erratic nature of assembly line production seemingly leave MUCH to be desired in terms of decent tolerances and the volume of lubricant that actually is applied to these various components during manufacturing and assembly!
Fact is, there are only *2* greasable points in ALL the drivetrain/suspension on my '02 truck, and as nearly as I could determine, the sealed rubber boots on virtually ALL those "greased for life" points were EMPTY of lube right off the showroom floor!
Seeing as how my regularly lubed suspension points on my old '91 at 120,000 were as good as new, I felt it advisable to do SOMETHING to improve the apparently poor setup on the '02, if it was to deliver similar longevity in it's suspension.
SOOooo - I obtained an injector needle from the local NAPA parts house:
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It merely snaps onto the standard greasegun hose, and allows piercing of the sealed boots on various suspension components to allow injection of the grease that often was missing at time of manufacture - as well as allowing renewing of lube as normal vehicle use is accumulated.
Here's a view of the needle in use:
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This is typical of other various greaseless suspension points - and hopefully I will avoid the early wear and failures some of our members have been exposed to...
2 hints are worth mentioning, 1. , push the needle WELL into the joint cavity to deposit grease on the FAR side, and allow trapped air ro escape from the pierced point when the needle is withdrawn - and 2. , do NOT overfill the joint - doing so might cause the boot to rupture - just inject grease to the point the boot begins to visually "plump" - and that's it!
NOW, a FEW here will suggest that piercing the sealed boots will in itself lead to contamination of the lube and early component failure - but the piercing act causes VERY little damage to the boots - and even at that, is FAR less than the older UNsealed greasable boots that served so well for so many miles.
Some owners have gone to the trouble to actually drill and tap each joint in order to install grease fittings - probably also worthwhile IF care is used to not introduce drill particles into the joint - but my way seems to do the job quite effectively, with FAR less effort! 
Fact is, there are only *2* greasable points in ALL the drivetrain/suspension on my '02 truck, and as nearly as I could determine, the sealed rubber boots on virtually ALL those "greased for life" points were EMPTY of lube right off the showroom floor!
Seeing as how my regularly lubed suspension points on my old '91 at 120,000 were as good as new, I felt it advisable to do SOMETHING to improve the apparently poor setup on the '02, if it was to deliver similar longevity in it's suspension.
SOOooo - I obtained an injector needle from the local NAPA parts house:
It merely snaps onto the standard greasegun hose, and allows piercing of the sealed boots on various suspension components to allow injection of the grease that often was missing at time of manufacture - as well as allowing renewing of lube as normal vehicle use is accumulated.
Here's a view of the needle in use:
This is typical of other various greaseless suspension points - and hopefully I will avoid the early wear and failures some of our members have been exposed to...
2 hints are worth mentioning, 1. , push the needle WELL into the joint cavity to deposit grease on the FAR side, and allow trapped air ro escape from the pierced point when the needle is withdrawn - and 2. , do NOT overfill the joint - doing so might cause the boot to rupture - just inject grease to the point the boot begins to visually "plump" - and that's it!
NOW, a FEW here will suggest that piercing the sealed boots will in itself lead to contamination of the lube and early component failure - but the piercing act causes VERY little damage to the boots - and even at that, is FAR less than the older UNsealed greasable boots that served so well for so many miles.
Some owners have gone to the trouble to actually drill and tap each joint in order to install grease fittings - probably also worthwhile IF care is used to not introduce drill particles into the joint - but my way seems to do the job quite effectively, with FAR less effort!
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