Don't think anyone is offended?
Back to the original question,
"Is it normal to have to remove so much material from a brand new bushing?"
How much exactly is "so much"?
What was the ID before you started and what is the pin size?
But as mentioned earlier basically if you still have well defined grease groves on the inside of the bushings then all is well, you removed what you had to to get the pin to fit, and the bushings were likely the right ones.
Again, it is normal practice to ream kingpin bushings after they have been installed, just as your service manual said you'd have to do (except for 1/2 ton).
This allows for any small inaccuracies in the spindle bores and their alignment to be of little consequence because the bushings are then reamed together with the same centerline, for a snug and long lasting fit ion the pin.
The point we were trying to make is that if you ream or hone the bushings individually you very likely miss out on the whole design and plan of ream in place king pin bushings.
Grigg
