2G 2GNT Rear Knuckle ES Bushings

[dewoof01]

Hoping for some help here. I've been working on a complete suspension rebuild this winter and I got the front completed now I am doing the first side of the rear. I've been installing the ES master Bushing kit. The front went fine, pretty easy, especially since i have a press and alot of tools. Now on the rear I'm having a hang up and I cannot figure it out. I got all the bushings out. However the 3 rear knuckle bushings, I think part number 8165 will not press in. I have been trying to press them in however i have it pressed so hard that the bushing is about 1/2" thick and the first flange part will NOT go into the opening. Its just smashing the bushing down. I know once that first flage gets sucked in it will go right through and pop out the other side but it won't go through.
Question is, can I take a hacksaw and cut the bushing in half then install each half from each side so i can avoid having these issues with the flange? Seems like there wouldn't be a problem doing that, just wanted to see if anyone had done that and if it might cause a problem. Thanks.

 

[crimsondragon]

Stupid question but did you knock out the outer bushing sleeve? If I remember correctly the knuckles also have the thin sleeve like the control arms. Second question, have you tried squeezing the flange in with like a screwdriver while applying pressure? While you can cut it in half like what Prothane does, I wonder if there might be a reason for differences in design.

 

[dewoof01]

Yes i cut the sleeve out. And yes i tried with a screw driver to push the flange in because i've had to do that on a few of them on the front. This SOB just will not go in there. I was surprised that I couldn't find any info on this because I figured everyone had this problem, but i guess not. I'm fine with cutting them as I don't see since there are bolts securing them to the control arm they can't fall off, just curious if this would be an issue as well as wondering why I'm having this issue and no one else apparently has.

 

[Doubleot]

I just did these about a month ago and didn't have any issues, could you post up a picture of the exact bushing and place your trying to install it?

 

[dewoof01]

OK pic is below. The bushing is sitting on top of the spot its supposed to go in. There are three of these on this knuckle that are the same size. So far i have done probably 10 of the bushings on the car and none of them have been more than 5 minutes to press in, but this one i just cannot get to go in the hole and i'm assuming the other 2 holes on the knuckle will be ust as bad.

 

[2slow4now]

The knuckles hole may be too sharp. Try tapering the edge of the hole a little with a carbide bur/dremel.
They are a bit of a pain in the butt.

I usually apply a bit of pressure with the press then use a screwdriver to start pushing the lip into the hole or you can make a tool to squeeze the bushing. Take a piece of pipe that is shorter than your bushing and smaller diameter, cut it in half, tack weld them to a pair of vise grip jaws, then while applying pressure to the bushing you squeeze the lips in on the bushing.
Basically works the same way as a piston ring compressor. Squeeze it down so it will go in the hole.

The one I made was heavy wall conduit scraps I got from work.

At work so paintworks is the best I have. Make something like this.

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[dewoof01]

Good idea. I will try filing the edge of the knuckle holes down and kinda ramp them a bit to help that lip sqeeze in. As of now its too tight to take a screw drive to push the lip in, it just does NOT want to go in that hole. I'd be open to any other ideas people have. Thanks.

 

[crimsondragon]

Try extreme temperature differences. Heat up the knuckle hole with a hair dryer or heat gun. You could try putting the bushing in the freezer but I have a feeling that'll just make it stiffer and harder to press in.

 

[dewoof01]

Ok got it figured out. Thanks for the beveled edge tip as I got to thinking. When i took a closer look there are very small bevels on one side of the hole, I hadn't noticed them before as you could barely see them. I filed these down a bit more and made sure to ONLY insert from this side and while they were still much much more of a pain in the butt than all the others have been to put in this extra beveling and patience I got them all in in about 30 minutes. Now I just got another side to do next week. Thanks guys.

 

[twicks69]

Bevel edge install along with some SilGlide works wonders. As well, for future reference, the Prothane kit knuckle bushings are 2-piece and are a breeze to install.

 

[2slow4now]

Bevel edge install along with some SilGlide works wonders. As well, for future reference, the Prothane kit knuckle bushings are 2-piece and are a breeze to install.

I like the prothane kit alot more because you get the rear inner control arm bushings too.

The other thing you can do to install them without a press or if your having stubborn ones is just use some large fender washers and a bolt and nut to sandwich the bushing into the hole.

Sorry no cheap paint works tonight. Just look at it as the fender washers are your bread and the bushing and hole is your PBJ and you just have to smash the sandwich together with the bolt and nut right through the center of the sandwich.

 

[97_4g63t]

I just used two hammers to put mine in. One hammer on top of the bushing and then hit that hammer with another. My front and rear all went in in one hit. Took me about 10 minutes to put one whole side in. Idk why no one else does them this way.