Front diff bushing replacement

[multihull]

While I was removing the transmission and undoing the front drive shaft last weekend I pushed up on the diff for some extra leverage and the diff clunked up wards. Bugger the rear diff bushing has finally failed.
So there's another job to do. Gee this 210,000km service is becoming a vehicle rebuild. So I remove the diff tonight and extracted the bushes. Ready for the new ones to go in tomorrow morning.
So far this means both front and rear drive shafts have been removed, the transmission cross member, the transfer case which I'm changing for the spare one with the new chain installed, the transmission is out and in pieces, the CV and half shaft removed, the steering knuckles disconnected, tie rods disconnected, the front diff drained and out. Or it's easier saying only the engine and rear diff are left in the car.
WOW, thats a heap of gear removed, I just hope I can remember how all the parts go back together and I have no spares parts or bolts left over.

[hotqld]

I replaced my front diff bushes a month ago @ 167,000klm previously I replaced them @ 97,000.

After I installed mine I noticed they had gaps in the rubber moulding at 180 degrees, mine are installed one at noon and six and the other at
10 and 4 o clock.

I suspect there is a correct orientation that I never got that sussed out as too late I had already installed them with a very big sledge hammer and large socket!

[multihull]

Originally Posted by hotqld

I replaced my front diff bushes a month ago @ 167,000klm previously I replaced them @ 97,000.

After I installed mine I noticed they had gaps in the rubber moulding at 180 degrees, mine are installed one at noon and six and the other at
10 and 4 o clock.

I suspect there is a correct orientation that I never got that sussed out as too late I had already installed them with a very big sledge hammer and large socket!

The standard way is to have the bushing slot at 6 o'clock. There is no slot or keyway in the bolts or any other part I believe they just do this so it helps you align them the best way for the direction of load or force on them

[multihull]

I've seen all sorts of methods on removing these bushes on YouTube and they all look violent and time consuming. Here's a really easy method where you just give them a few firm taps.

Just place a hack saw blade through one of the bushing slots then re-connect the hack saw then make a cut through the bushing . Then disconnect the hack saw from the blade and do the same in the next hole slot. Make sure you cut straight and true so you only just cut through or almost through as you don't want to make a big cut into the housing. Once you have 2 small hack saw cuts the bush springs in and then the bush just taps out extremely easy.
I then finish off by cleaning the rusty housing hole with a round wire bush in my electric drill. Before I insert and press in the new bush I smear grease around inside the housing hole and around the extenal metal bushing to make it easier for pressing and help prevent rusting in the future

[JamesLaugesen]

Originally Posted by multihull

I've seen all sorts of methods on removing these bushes on YouTube and they all look violent and time consuming. Here's a really easy method where you just give them a few firm taps.

Just place a hack saw blade through one of the bushing slots then re-connect the hack saw then make a cut through the bushing . Then disconnect the hack saw from the blade and do the same in the next hole slot. Make sure you cut straight and true so you only just cut through or almost through as you don't want to make a big cut into the housing. Once you have 2 small hack saw cuts the bush springs in and then the bush just taps out extremely easy.
I then finish off by cleaning the rusty housing hole with a round wire bush in my electric drill. Before I insert and press in the new bush I smear grease around inside the house hole to make it easier for pressing and help prevent rusting in the future

+1

I used the same method with a reciprocating saw. Just one cut in the bush was enough (probably a thicker blade.).
To protect the housing I put a piece of tape over the small lip that the saw is cutting towards, so that the tape is knocked off when the blade gets close.

The quotes that include removing the diff are insane.

[briteway]

I think next time I do mine I'll just pull the diff out. It took me ONE minute to replace when I had the diff out at the time of superlift install.