Rear axle beam bushings, Need help

hey guys

so i got the old bushings out in 20 min. ive spent the last 6 hours trying to get 1 in, and as soon as it got 1/2 way in the dam beam... it BROKE

Need help... im going insane and very aggravated with this car.. tips tricks?

i tried them in the freezer, and torched up the pocket... managed to burn a few fingers

tried shaving down the plastic to have a slimmer fit... couldnt get it to stay straight and would pop out sideways 1/4 of the way in.

built a puller to pull them in... got it 1/2 way in and the bushing plastic snapped and went out sideways.

im loosing my mind...
thanks

-Rob

also, where can i get a new bushing or 2?

Get GOOD bushings, don't go by price!!

OEM some BOGE, not Mehle, First Genuine Parts and something else that sounds like OEM parts.

Junk, barely round.

I have a tool I rent to install quality bushings.

If you're interested PM me.

i read the vwvortex posting before doing, the C clamp did nothing, i built a installer to pull it into the flange... it went 1/2 way in when the plastic housing broke.

i dont know where the bushings were purchased from, its to late today and no dealers will be open tomorrow to retrieve a new one.

The original bushings had a steel outer lining, did you make sure that it was removed down to the bare walls? I found that greasing the bore before putting them in was the best way. My first time I did them I had the hardest time getting them in. I tried using a bearing press but a C-clamp and two pieces of wood worked best.

Rodrigues said:

The original bushings had a steel outer lining, did you make sure that it was removed down to the bare walls? I found that greasing the bore before putting them in was the best way. My first time I did them I had the hardest time getting them in. I tried using a bearing press but a C-clamp and two pieces of wood worked best.

Click to expand...

yes, all the original steel outer case is removed, the hole was cleaned with a wire wheel and sand paper, lubed with high temp grease, and wd-40 was on the bushing.

i have one bushing left, im tempted to give it a shot on the other side... have to wait till monday to call local dealers for a new one.

The whole bushing gets put under a lot of stress as it's being pressed in and you can see it sort of squeezing together as it's being forced in but I would have never guessed it was capable of breaking. The only time I could see it break is if the bushing starts going in crooked. I think the first time I did it on a car the tolerances were a lot tighter than the second time because I remember telling myself "that was a lot easier". Maybe the bushings or the bore aren't exactly consistent from car to car and bushing manufacturer to bushing manufacturer.

Rob02f350 said:

yes, all the original steel outer case is removed, the hole was cleaned with a wire wheel and sand paper, lubed with high temp grease, and wd-40 was on the bushing.

i have one bushing left, im tempted to give it a shot on the other side... have to wait till monday to call local dealers for a new one.

Click to expand...

Not that I would now, but do you think you just got a bad one? Perhaps the same method with a new bushing will work?

I'm looking at having to do this soon myself..... but I have access to a hydraulic press. Anybody know if that will work? I read in another thread that some guy got turned away by shops that didn't know how to get the axel in the press. I'm wondering why. By the look of it, it's kind of a "maybe"... the housings for the bushings certainly don't sit out far enough to to get the centers to line up with the center of the press, but so what? Also trying to figure out if it's possible to remove use a press to remove the old bushings.

You're too far away for me to make the offer, but if pressing them is giving you that much grief, is it possible to get them pressed in at a shop?

Wrong bushings, steel outer is 69mm and the plastic is 72mm, get some more steel ones

Some 2000 have the old steel beam with smaller bushings.

http://forums.tdiclub.com/showthread.php?t=301131

Rent the tOol from Davebugs. You'll be glad u did!

I think there might confusion? This thread inspired me to go out and do my own because I've had the parts on the shelf for a while and just haven't gotten around to it yet. There is a "reducing sleeve" in there that the OP might not have noticed.

Here is the main outer bushing area:



Here is the "sleeve" already starting to come out:



Here is the tool I made for putting them in, notice the slot cut out to relieve pressure from the protruding nub:



Tada:




Takes longer to remove them!

Give me a call when you can 603-529-5510. I have the KT tool, and I'm going to be back in NH this evening, and back in the shop tomorrow morning.

-Rich

Hey guys

i went to Napa, got some with a name Meyle for MFG, lubed them up. used the press i set up and the went in slicker then hell. a few min each side to press them in.
http://www.napaonline.com/Search/De...41C_0257286939&An=599001+102000+50074+2074021

Might not be the best, but i know it worked for me with out a problem.

Definitely bad parts. there in the trash now. and dam the car drives better!

I'm sure it's fine

Rob02f350 said:

Hey guys

i went to Napa, got some with a name Meyle for MFG, lubed them up. used the press i set up and the went in slicker then hell. a few min each side to press them in.
http://www.napaonline.com/Search/De...41C_0257286939&An=599001+102000+50074+2074021

Might not be the best, but i know it worked for me with out a problem.

Definitely bad parts. there in the trash now. and dam the car drives better!

Click to expand...