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DB7 - Removal of stock bushings, Installing poly bushings

Things to note:
This is part 3 of this particular write up. Please see, part 1 and 2 for further details and to get caught up to this point.

Please note before you start this project, to remove the upper and lower ball joints you will need a very large C-Clamp that can be rented from the auto parts or a press. There is also a specific socket adapter kit you must also rent in order to use that C-Clamp method. Honda's have interesting front control arms that won't allow you to push that ball joint out with out. In my case, I have a 4 point 66mm impact socket that worked just fine. If not, I would have needed to rent the secondary kit that comes with the extra adapters.

This kit from Advanced Auto looks like it comes with everything: Powerbuilt Tools Ball Joint...

The scope of this project was to replace:
Lower control arm bushings.
Lower shock mount bushings.
Tie rod ends.
Lower ball joints.
Upper ball joints.
Sway bar end links.
Upper, inner, A-arm bushings.

What are we doing this round?
Installing poly bushings on the lower control arms and the stabilizers.

Tools needed: 
I'll tell you the tools that I used for this process however, this one may take a bit more noodling on your end. If you have a press or know someone with a press this would go much faster.

Removal of the lower control arm bushings:

  • Propane torch.
  • Large screw driver.
  • Vise grips or larger pliers.
  • Jigsaw or a hand saw.
  • Chisel.
  • Large hammer.

For the stabilizer bushings:

  • B series Honda head bolt. 
  • x2 racing harness floor plate washers.
  • 66.5mm socket. Also know as a 4 point AWD socket.
  • Socket to match the bolt.
  • A thick washer that just fits through the diameter of the bushings in question.
  • Wrench to match the nut.

We start by burning out the bushing material. This is the slow and "painful" way. If speed is what you need, a press will have to be on the deck.

After you get the bushing material all out you will need to get the rest of the metal jacket that once head it off of the arm. 

 The method that worked best for me was to cut a slit top and bottom. Then, tap a chisel in there. Once the metal starts to peel like shown above, its cake. Getting to that point is the frustrating part.

Once you get all four jackets out you can have a little old jacket party on your workbench. 

The get the poly in there are several methods, however the one that worked for me was to use some washers and a long bolt to pull the new poly bushing in place. That process is elaborated further below. 

For the lower arms an Alternate through bolt of a D series or B series did the trick. A couple washers laying around that were big enough for the openings and a nut to fit the bolt. 

This is my "contraption" laid out on the bench for the stabilizer bushings. You get the idea here. All we are trying to do is create a mini press to bush the bushings in. You could use the large C-clamp you rented as well I'm sure. I had to return it before I got to this point and was not going back out for it.

Here we are watching that large washer squeeze the old bushing out and in to the large 66.5mm socket on the other side. 

Just keep tightening. The bushing is mid way through now. I also used some spray lube to keep things moving.

Once it got 95% of the way through, I pulled the socket off. The downside to this method is now you are going to have to get that old bushing out of the inside of this socket. I'm just making things harder on myself. Remember that press idea?

There we go. The old one is completely out. 

Now time to "press" the other one back in. Same method here just in reverse so to speak. Instead of pushing the old bushing all the way through, we are simply pushing it in to place.

There we have it. Once you get all the poly bushings in place and reassemble the arms you are ready for install. This was the most lengthy of all the processes so far. Again, having a press and proper tools for this one would have made it much faster. All in all, not too bad though.

I also took the time to paint the arms up with some Rustoleum Semi Black to keep things clean and tidy. I figured why not, I wasn't in a hurry on this one anyway.

Next up, lower ball joints.


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