Frame bushings

[stonefox]

Friends,
Upon getting back my frame from the Galvinizer,I have to reream the frame bushes.The replacments are 1.196 -1.198. How much under size should they be to be tight but not impossible to install.Does anybody have the factory spec or have a frame with out one in it? I'm thinking 1.1875 or 1 3/16. thanx

[I Leak Oil]

Never thought of it before and I don't know what the answer is. .009" sounds like a lot for a press fit on those though.

[Mountain132]

Do yourself a favor and go poly. I had the same problem and spent days trying to get the factory bushings in. I got the 2 rear and only 1 front in. I had to find someone with 1 poly bushing for the front. I was snapping 1/2 grade 8 bolts trying to pull them through. Not worth the trouble. Not to mention when you get them stuck you have to drill and saw them out, complete waste

[albersj51]

With poly bushings, like great basin rovers, is the fitment after galvanizing less of a hassle since they don't slide all the way in like rubber bushings?

[Mountain132]

I think it's more because they have some give to them so the diameters don't have to be a precision match, it does help that you can push them in from both sides. You can do it by hand or may need a rubber mallet to get the inner sleeve in.

The factory rover ones are so tight that you might as well be trying to push a solid piece of steel through the hole. If they don't go in, they don't go in

[albersj51]

ill probably go that route. So the polys would require less reaming of the frame after galving to get them to fit? If so, thats another advantage since you're less likely to wear through the zinc and therefore risk rust.

[masonater]

I think it's more because they have some give to them so the diameters don't have to be a precision match, it does help that you can push them in from both sides. You can do it by hand or may need a rubber mallet to get the inner sleeve in.

The factory rover ones are so tight that you might as well be trying to push a solid piece of steel through the hole. If they don't go in, they don't go in

I can vouch for that!! my 12 ton press could hardly do it, even after putting the bushings on the lathe and taking a good amount of material off.

[Mercedesrover]

I can vouch for that!! my 12 ton press could hardly do it, even after putting the bushings on the lathe and taking a good amount of material off.

That is a great picture.

After following a RRC in the Anza-Borrego Desert and getting pelted with chunks of blue poly-bush until they were gone, I'm not sure I'd trust them myself.

After I galvanized my 109 frame I reamed the holes out with a bit of course sand paper wrapped around a socket driven by an impact wrench. I drove the bushings in with a ball-joint press. It's not my favorite job but it worked well enough. As far as clearance goes, I'd think no more than a .002"-.004" interference fit. Leave it a little loose and use some Permatex bearing and sleeve mount if you're worried they'll spin.

[Terrys]

I'd say anything more than a few thous (3-5)and you would be hard pressed to get them in. WOW that was a pun not intended. I've done them hitting the frame with a rosebud torch while the bushings were in the freezer overnight, without a major pain, but you can't waste a lot of time. I used a long threaded rod and impact wrench. For all the agro it may seem, it's a lot better than listening to the clunk of sliding busings everytime you make a hard turn. I recently replaced the rear crossmember in my 88 and those bushings can be pushed side to side with your thumb. Since the inner tube is longer than the outer, your shackles tighten up up on the inner tube with about 1/8" clearance on both sides, allowing a loose bushing a country mile to wander back and forth.

[stonefox]

Thanks for your response. Being I already have the factory bushs thats what I'm going to use.I'll let you guys say "I told you so" if it goes bad.
Mercedes, I looked into the Permatex stuff and found three differt ones, "for a close fit ", "for a relaxed fit",and "for a worn fit".I wasn't sure if you were sending me to buy a pair of jeans or what? They all seem to have similar specs.
By the way,what is the importance of this super tight fit anyway if the bushes are held captive by the shackles?They won't slide out from side to side.What would it hurt if they did spin a little ,it would seem that they would wear more evenly? Just wondering

[I Leak Oil]

You don't want the outer sleeve to spin because it will wear into the frame, causing it to become oversized. THAT doesn't sound fun to fix!

[Terrys]

By the way,what is the importance of this super tight fit anyway if the bushes are held captive by the shackles?They won't slide out from side to side.What would it hurt if they did spin a little ,it would seem that they would wear more evenly? Just wondering

The shackles are tight to the inner sleeve, not the outer, which is recessed a good 1/8" on each end. The overqll length of the outer sleeve is the same as the frame, so if the bushing isn't tight, it will slide back and forth a 1/4", with a good clunk on each end. I have to think this woulld also cause handling issues, un-even rear tire wear, and shorten the front bushing life also.

[stonefox]

You don't want the outer sleeve to spin because it will wear into the frame, causing it to become oversized. THAT doesn't sound fun to fix!

Well that makes sense Jason. I knew deep down ,you weren't totally full of BS.

[I Leak Oil]

Awe shucks, thanks Sean.
Seriously, though, Terrys answer is spot on also. You definitely don't want the outer casing to spin in the frame.

[stonefox]

Its all becoming clearer now......You fellas are swell!