Bush Removal Tool, Sump Removal

This weekend I managed to get all the front spring and chassis bushes out.

I wound the chassis bushes out with a tool based on a piece of threaded rod (from an old scissor jack), a big socket, and two pieces of metal machined to push the bush from the other side and follow it through without crumpling under pressure. This tool will stay on my shelf for many years to come.. (Thanks again to my friend, Jacob, who machined the two 'push' pieces on his lathe!)

30 second chassis bush removal..

The bush tool (with extracted bush still in place)

Spring bushes will come out by hand with a shim (old screwdriver) knocked under the grip leaf to loosen its grip on the bush. Still, you need six pairs of hands to hold everything still and level enough to hit the bush with enough force to get it moving. But it can be done. I eventually bolted a 22mm socket to each bush with an old shock absorber chassis bolt to hold it in place so I could concentrate on hitting it as hard as was needed with a club hammer.

I used the tool to wind in the new spring bushes with plenty of copper grease around them. I was able to do it neatly like this, and did not have to knock the new ones about in any way to get them aligned correctly in the leaf. I will insert the new chassis bushes in the same way.

Old front bushes

I've bought plenty of cheap graphite grease from a nearby John Deere outlet so am now ready to reassemble the front leaves and refit them. I just need a new, squared off U-bolt, for the centre side of the axle casing on the O/S. I've been sent a rounded one, which I believe is wrong.

Sump Removal

I also removed the sump this weekend, as it made it easier to wind out the N/S chassis bush with my threaded rod, and I figured I could combine the task with one of the first service points.

The old oil was thick, black and burnt. Looking up into the block everything looked wet and in good condition, to the eye at least, which is reassuring. I have 10L of new 20W-50 waiting in the garage for when the sump gasket and new oil filter arrive. When they do, and I've cleaned the sump and filled her up again, I'll reconnect the battery and turn her over until I see the oil pressure come up. This will splash the new oil up into the block and fill the new filter at the same time. She won't start yet of course, as the petrol tank is off in preparation for welding..

Bush Removal and Spring Refurb Progress

When I came to remove the first chassis bush, I did try my luck with a hammer and cold chisel first but did not persevere too long. There was no slight sign of movement, nor glimmer of hope!

I turned my hacksaw blade upside down and cut through the inner bush sleeve, rubber, and carefully through the outer sleeve without scoring the chassis itself. I was then able to knock the inside parts out, but was left with the outer sleeve still stuck in place. Having removed a 1mm strip from its perimeter I was confident I'd knock it out in no time when I returned the next evening (it's still waiting for me).

When I tried to remove the first spring bush, I had an even harder time. I've heard all the hints and tips about a screwdriver or shim either side to release the grip leaf enough to knock the bush out - but I could not get this approach to work.

So I set about making a tool I could use to remove bushes. With limited free time, my mind was starting to add up the weekends it would take to get through the 12 bushes that are on the vehicle in total..

I took some threaded rod from an old scissor jack and some other bits of scrap. A couple of failed attempts (where some piece of the tool would give way before the bush moved) saw me enlist the help of a friend with a lathe (thanks, Jacob!). He machined me a cap of the right dimensions to push the bush from one side, out and into a receiving cup (a very big socket in this case, but sturdy pipe would do the same job).

With this, I was able to get the other chassis bush moving:

I will cover this tool in detail once we've machined the final piece, a steel cylinder of the right size and strength to lock in place behind the push cap and follow the bush all the way through. We need to bore the centre out a few thou. I've used some scrap tubing in place of this stronger piece but it always crumples before the bush moves, such is the force needed to push past the corrosion and tight fit. More soon..

In other news I got the two front springs apart; a big hammer, cold chisel, sweat, blood, and tears being the main ingredients. There is also a knack to it, but it's hopeless to explain. Take one apart with some pain and swearing, and you will learn enough to take the second apart in almost no time at all. Often the way!

Initial estimates of "they don't look too bad" have proved correct, but they will still benefit from the clean-up they're getting and the grease I'll pack them with and a light spray of Chassis-in-One once they're back together.

Hopefully, the next couple of updates will detail the bush extractor tool and show a pair of refurbished leaf springs ready to go back on the front!