Race (and 1JZ) Buildup Journal

11/15/2003 - Suspension Bushing Removal

Part of my race build up is to remove any compliant components from the suspension because they cause undesirable alignment changes under stress (such as turning a corner). I took part in a group buy for a complete set of 22 nylon bushings that replaced all rubber bushings in the suspension.

After removing most of the suspension from the car (all but the rear spindles and rear upper arms, which are going to be difficult), I had to remove the bushings from the arms. This is much more difficult than it sounds, especially if you don't know how to do it.

First, Toyota never intended the bushings to come out. If they go bad, you replace the entire link or arm. Second, they are DAMN tough things. The rubber Toyota used is very high density. The upper arm (aluminum) are a direct rubber to aluminum fit. Even so, getting the bushing out is very hard. This doesn't even consider any of the steal arms, with steal sleeved bushings. I actually bent a lower control arm (luckily I had an extra) before the bushing came loose!

So, to save everyone else some time, I'll explain the tricks. First, do the upper arms. They are aluminum and therefor delicate. Note that the outside edge if each bushing is not rubber like the inside, but a metal lip. You must catch this lip (not the arm) in a vice and bend it up. Note the two pictures below of two different upper arm bushings. One is very neatly bent. That one was done later after we had it worked out. The other one (mangled badly) was one of our early attempts. Either way, you can now use a vice to press the bushing out. On the inside, place a large socket against the rubber and/or center pin. On the other side, use 2 sockets to catch the aluminum race for the bushings. Simple crank the vice down and the bushing will come out. NOTE: Wear eye protection. Chromoly can shatter and most sockets are Chromoly...

The lower arms are more problematic. I started trying to use a press (~25 tons). I have a new respect (read fear) for hydraulics. Nothing, and I mean nothing stops a press if you don't let go of the control. It will crush just about anything... To use the press you need fairly exact dies, one to press the center steal sleeve, and one just larger to press the arm against. Because of the lip on the sleeve, this is very difficult to do. My first attempt was not to use the back die to press against, but to press one of the bushings against the rest of the arm (I had a spare, so what the hell). The result as a bent arm. The sleeve is in there that tight.

The correct solution is to cut the rubber center out. I actually use the press for this, but a wire saw would work (drill a small whole in the rubber, feed the wire saw through and cut around the bushing). At this point you will be left with just a arm, sleeve and some rubber. The final step is to cut the sleeve long ways. As soon as you finish cutting it, the bushing will come right out. This works for all the the steal sleeved bushings.