I replaced the tiny 8"x2" front casters on my new Invacare Storm Torque 3 with the entire fork assemblies from one of my previous chairs (with air-filled 9"x3" tires). However, after a few days of use I started getting these terrible cracking noises from both caster stems every time I turned any direction, and each day it just got louder and louder and seemingly tougher to actually turn.
I chalked it up to bad bearings so I purchased a set of 4 replacements from Amazon (99502H-2RS Double Sealed Ball Bearings 5/8 x 1 3/8 x 7/16 Inch, for those interested), and installed them over the weekend. Vastly improved sound and turning capability initially, but now 48 hours later I am getting the same symptoms with super loud cracking noises and harder turns.
So, I am now assuming I am not assembling this correctly and I am killing the bearings. Does anyone know the correct sequence and number of spacers to install along with the bearings? Bringing the stem up from underneath, I am using 1 bearing all by itself with no spacers on the stem. Then from the top down, I am putting another bearing down first by itself, then I am using a white spacer next, then the nut to ratchet mostly tight. I am not adding any additional grease anywhere either.
Am I doing this anywhere close to correct?