Differential Bush removal options

Rusty

You could try Z1's removal tool. But it's a piece of chit.

If you are installing a SPL bushing. Put it in the freezer for a couple of days. Or pack it in dry ice. If you are installing a poly bushing. They like to squeeze out at the sides when being pulled in. The bushing hole is not perfectly round. It's kind like egg shaped. It got that way from the welding.

The oem bushing has 2 chambers with silicone fluid. The one that's leaking, you don't have to worry about. The one that ain't leaking will spray fluid about 3 ft when you start to cut in to it.

Once you have the diff out. Work from the front of the bushing. Use a 1/2' drill that you plug in. You could smoke a cordless drill. Cut out the inner bushing using a 2" hole saw. I linked it below. Then using a sawzall. Make 2 or 3 cuts in the outer shell. One at the bottom of the shell. The other ones at the 4 or 6 o:clock positions. Being careful of not going too deep. Stop and inspect your cuts a couple of times. Once you have your cuts done. Use a muffler tool. Link below. Position the cutting edge of the tool with one of your sawzall cuts. You can hammer it out, or use an air chisel and you will be done faster.

Once the outer shell is out. Use a 2", 40 grit flapper wheel on a drill or die grinder to remove the paint and smooth out the inside of the hole. Link below. MAKE SURE THAT THE INSIDE OF THE HOLE IS BABY BUTT SMOOTH! If you have any burrs or metal sticking up. You will not be able the fully install the bushing. As it will hang up on the burrs. And you are SCREWED! Once you have the hole cleaned up. Anti seize the chit out of that hole. Install the bushing from the front. You will have more working room.

To install the bushing. I used a piece of 1/2" threaded rod about 14" long. Double nut the one end of it. 2 pieces of 3/8' thick, 4x4" squares with a 1/2" hole in the center of them. On the thread rod, put a couple of 1/2" washes on it and slide them back the the double nuts. Take one of the plates and position it on the rear of the hole. Then put the threaded rod through it. Put you bushing on the rod, followed by the 2nd plate, a couple of washers and a nut. Finger tighten the nut up. Make sure the bushing is squared up with the hole before tightening the nut up with wrenches. Once squared up, start to tighten the nut. Once you can't turn the wrenches anymore. Use a hammer and beat on the plate. You will have to repeat this a few times. Once you have the bushing flush with the hole. Remove the plate and put a big socket on the rod, followed by the plate. You want the bushing about 1/8" to3/16" below the front of the hole. If you don't get the bushing far enough in the hole. You will have trouble installing the front 2 bolts.

Use this hole saw. It cuts deeper then any hole saws.
https://www.homedepot.com/p/DIABLO-2...00CT/301697691

Muffler inner pipe cutting tool.
https://shop.advanceautoparts.com/p/...B&gclsrc=aw.ds

Flapper wheel
https://www.premiumtool.com/flap-wheels/

Good luck on your install. I've done a few of them.

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