Differential Bushing Removal
 

So I've read Jimlab's bushing post and it worked for the other bushings (with some heat added), but those X%&#1-ing differential bushings managed to bend two 1" 1018 steel bars stacked on top of eachother. Anyone got any other tips for getting those things out?

bump

If all else fails, take it to a machine shop...

I pressed some out that were majorly stuck.

I used a pair of very large sockets. One to receive the bushing and one to push the bushing. I had my 12 ton press to the point where I couldn't budge it anymore and the bushing hadn't moved yet. I was quite impressed with that! :p: I flipped the diff mount over and tried pressing from the opposite side of the bushing and it finally popped free with a loud bang and come out.

If you need me to I can check tonight on what size sockets they were.

Soak the bushing in some Kroil or PB Blaster penetrant . . .

:-) neil

DamonB, which way did the bushing come out? Is there a flange or anything that keeps the bushing from coming out in one direction?
I've tried the kroil thing and it didn't work on the 20 ton press, I even cooked the bushings with a torch and they didn't budge. I'm thinking I'm not pressing from the right direction. But yeah, if all else fails, it's machine shop time...

I don't recall now which way it finally came free but there is no flange; it should come out either direction. I think in my case having it so fully stressed and then flipping it the other way just finally broke it loose. You might also try stressing it as much as possible in the press and then banging on the side with a hammer. This should help free it up.

I've done several sets of diff bushings and only had trouble with one. On that set the diff mount was visibly corroded and that's why the bushings were stuck. The other sets pressed out with no difficulty.

Unfortunately, the mount is rusted enough to cause a problem. I'm gonna try kroiling the shit out of it tonight and then pressing from the other side. If that doesn't work, I'm gonna try a machine shop. I'll post the results.

Mine both came out pressing toward the center of the bushing bracket.

What I did was use a piece from the autozone ball joint press rental tool...their largest steel cylinder...to catch the bushing. On the press side of the bushing I used what I believe to be a 1-15/16 socket (would have to check to be sure). I placed a piece of steel stock over the 1/2 drive of the socket so the press was pressing on a flat surface. Then I just went to town on the press.

It first moved with a very loud bang...almost like a gunshot...then slid rather easily the rest of the way.

The socket and ball joint press cylinder made it an easy job.

How big of a press were you using? Did you use any kind of oil? How rusted was the mount?
I'm very tempted to do the ol' burnin' it out trick...

The part of the mount that is sticking is the metal part...it is a rubber center encased in metal. You could burn out the rubber and take a sawzall to the metal...

My press was I belive a 10 ton. There wasn't much corrossion...but I almost had to hang on the jack handle to break it free. I was pretty worried when I was doing it, and the gunshot sound of it breaking loose scared the hell out of me.

The real trick is getting a socket the pushes on the metal part of the bushing and nothing else...but is small enough to fit through the bracket. When I get home I will check the size. Then you still need some sort of cylinder to 'catch' the bushing as it comes out.

I'm thinking a 2" pipe should suffice to catch the bushing. I am hoping I'll be able to find a piece of metal which will be able to evenly press down on the bushing. Plus I need to get some more Kroil... I'd love to get that size from you though.

Yep. It lets you know you're alive doesn't it? :p:

I used a 2 3/8" Craftsman socket to catch the bushing and a 1 3/4" Craftsman socket to push the bushings.

1-3/4" was the socket I used to press, too.

The cup I had in the autozone ball press kit worked perfectly to catch the bushing so if you have one of those in your area you can save the money you would have spent on the other socket...it is also the tool you need to do your pillowballs. I did all of that at the same time, so I had it laying around.

Ok, so I got a piece of 2.5" pipe and tried again with heat and kroil and... nothing. Wouldn't budge. My friend comes over and has a look and decides to try a different socket. Apparently it was too small cause we got a loud pop and a geyser of oil. So he got pissed and ended up just torching and cutting the bushings out. So that's that. Thanks for everyones help.

glad you got it sorted out ;o)

Where did the geyser of oil come from?

Those bushings are oil filled.

I used a 12 ton Harbor Freight press with an impact socket on the end of the press rod. I used the edge of the socket against the metal ring of the bushing and pressed it out. My HF prss came with two cast iron press plates. It wasn't that bad at all.

The difference between liquid filled and solid nylon is HUGE.

This thread is making me think that my hand-operated bushing tool is not going to cut it.

For the diff bushings it most likely won't. They can honestly be the most stubborn if the car has seen some miles.

May need a "sharper" tool... ;)

I was able to get my diff bushing out with the loaner tool (c-clamp) from Autozone. It's the same tool I used for the pillowball bushings. The diff bushings took a lot of work with two people holding the various parts. Most importantly, we tightened the bushing tool with a cordless impact wrench. I couldn't imagine cranking on it with a handtool/socket wrench. Also, I recommend clamping the diff mount on a bench vise to hold it steady. We used the included 2" ring/pipe as a receiver and a 1 3/4(?) metal end cap that I found in the pipe section of Home Depot. The end cap was a perfect fit to press against the metal housing of the OEM rubber diff bushing. BTDT, the old bushing does not have a flange and can be pressed out either direction. Good luck!

If all else fails, propane torch and hacksaw. It's a little brute force for my tastes, but it worked awesome.