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Or you could have 1.968" hubs, and 1.938 caps.
Get a punch and put some dimples in the lip of the dust cap from the inside and reinstall. Can do the same for bearing buddies. here
Re: dust cap keeps falling off the hub
My dad kept loosing them for a wile, was told he used too much grease and since then, he re-did them with less and they have never fallen off again.
Re: dust cap keeps falling off the hub
I'm guessing you might have 1.810 diameter hubs, and are trying to keep 1.781 diameter caps in them.
I use JB Weld Epoxy to keep my Bearing Buddys on and water tight.
If you must remove one a block of wood and a hammer is all you need.
"Farmer Fix"……Just take a prick punch and carefully go around the inside and put some dimples "out". It’ll fit just fine. I’ve done it a million times with bearing buddies and conventional hub dust caps. here
drill …tap and bolts each side on the edge a solution .
I’d check the cost of new wheel hubs. I would think you are right about them getting enlarged. It may be worth the cost of replacing the hubs with new ones and saving yourself the headaches of limping the old ones along with Loctite. If I were to try Loctite, I’d probably use Red. You’ll still be able to knock the Bearing Buddies out when it comes time to service the bearings. My .02.
-Ben
Fisherman6 is correct. I had the same problem and a new hub with bearings at Northern Tool, for about $35, makes the problem go away. The bearing buddies will fall off at the most inconvenient times. Good luck.
The most common reason is the hub bore diameter is wrong, because the hub manufacturer did not maintain quality control during production. Other possible reasons are listed below. The spindle may be too long, which could cause the nut or cotter pin on the end of the spindle to push against the Bearing Buddy® piston (when grease level is low), eventually forcing it out of the hub. Excessive removal and reinstallation of a Bearing Buddy® can wear down the Bearing Buddy® shoulder (the part that fits into the hub), which decreases the interference fit between the Bearing Buddy® shoulder and the hub bore. An out-of-balance tire and/or incorrect bearing torque can cause excessive "wheel play" or wobbling, which can cause a Bearing Buddy® to work its way out of the hub. Installing the wrong size Bearing Buddy® for the hub bore diameter. Theft.