Need help Aluminum Bushing sized in steel.

[Jkstang78]

Hi everyone I am new here. Found this site and hoping I can get some help.

I am restoring a 1981 Mustang. Someone had put a 8.8 Lincoln mark 7 rear in the car. They Also installed an Aluminum bushings in the rear. Now 1 bushing is completely sized and I don't know what to do to get it out. I tried spraying WD40 to get it to soak in.

Maximum Motorsports sells this tool to get out/install stock style bushing. Which is what I am trying to put back in. But I already stripped the bolt. I found another bolt with a 9.8 grade. I tried to use this bolt with an impact gun to shock it out. I snapped the bolt in half.
http://www.maximummotorsports.com/Rear-Upper-Control-Arm-Bushing-Tool-P190.aspx

So now I don't know what else to do. I was thinking of trying to cut both sides flush. Then using a hammer and big socket to and hammer it out. But before I do that. I want to see if anyone has any other ideas.

This is the one bushing I got out.
https://scontent-lga3-1.**.fbcdn.net/v/t31.0-8/19800805_10213621713602901_4649181895861332753_o.jpg?oh=f71f1edb20dfbcee21e449ebb6461269&oe=59C3132F
https://scontent-lga3-1.**.fbcdn.net/v/t31.0-8/19944335_10213621715922959_7407151363777510220_o.jpg?oh=472c9319147993f29e8532bf7f8cf19c&oe=5A0E9767
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/19990282_10213621181069588_1459847261175915321_n.jpg?oh=13ea53a42e4ddae5c8e02129dd21d146&oe=5A072D6B

 

[larry_g]

Go at it with a hack saw or recip saw and quarter the bushing. Be careful not to cut the rear end housing.

lg
no neat sig line

 

[LXCam]

You go hammering on that and you'll likely bust the tab off the housing. Cut it flush, both sides, take a torch and heat up the tab and try to keep the flame off the bush as best as possible. Then tap not hammer the bush out.

Also you can cut flush, then drill out the hole as large as you can, then cut thru one side. This will relieve the press fit of the bush and it'll pop right out with minor persuasion.

 

[Griff93]

If you have enough room, a ball joint press works great for this sort of thing.

 

[iajonesy]

Be very careful if you use the torch method because any heat on the bushing will cause it to expand at a faster rate than the steel material it's in. After you heat the steel tab, spray the inside of the bushing with contact cleaner immediately to help shrink the bushing down, making it a little easier to remove. Good luck.

Mike

 

[Cue]

I had to remove some of those from a mustang a while back, I used that tool basically but instead of the bolt I made a adapter on my lathe to thread the bolt into a hydraulic punch tool like this, got it right out.
https://www.harborfreight.com/hydraulic-punch-driver-kit-96718.html

 

[Jkstang78]

Guys thank you so much for some of the ideas. I cut both sides as flush as I could. I also had a 1-5/8" hole saw that I used to start drilling through. I thought for sure I was going to have to go all the way through. Then towards the end it started to break loose and turned out. Then I took a round file and use the file to clean up any rust and Aluminum that might have been left in there. The new bushing I put in. I put anti seize around the shell and it went in with no problems. I really want to say thank you to everyone.

https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/20108278_10213676015960426_8840389078488534805_n.jpg?oh=4ec58be9b6a7d1187e5876b5bc5d0b97&oe=59F7837E
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/20032070_10213676015680419_2088388429579704708_n.jpg?oh=6b23f3e55fda2603167672f9a1b90c68&oe=59C7CEBD
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/19990057_10213676016600442_3165221146644665292_n.jpg?oh=47f01b8b38aaf08b46d7bb51b52a88fe&oe=5A0B69DE
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/19989798_10213676017160456_864803869344365819_n.jpg?oh=f4ef009eadf56ef3fa6c8360cdc6b343&oe=5A0314FB
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/20031689_10213676017320460_2185633382166761574_n.jpg?oh=71062142a9b355973419823ea6a2ba71&oe=5A0B3581
https://scontent-lga3-1.**.fbcdn.net/v/t1.0-9/19990485_10213676018760496_2806943426852095105_n.jpg?oh=3300a89214f177ef74a3783559a7af2e&oe=59FDC546

 

[ChrisLS8]

I had this issue on a 240sx. What I ended up doing was tapping the hole with threads and using a slide hammer and a bit of heat.