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Modifications >> Suspension

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Pole120
Hard-core CEG'er

Reged: 03/16/04
Posts: 4141
Loc: New Berlin, WI
ES Bushing How-to....finally
#1276651 - 07/12/06 02:58 AM

Detailed below is the easiest way I’ve found thus far to install Energy Suspension's trailing arm bushing set. Total time of bushing install (removal/install of arms not included) about 1 hour. Please excuse picture quality; these were taken with my old digi-cam.


Tools needed

Propane torch
1 3/8" hole saw and drill
3/8 ratchet
9/16 socket
9/16 wrench
15mm socket
Breaker bar
PB blaster

Optional-

Air hammer with chisel attachment

Also needed

ES Bushing set
(1) 3/8-16 x 3 1/2" hex bolt
(1) 3/8-16 nut
(2) 1 1/4" OD washers
(2) 1 3/4" OD washers


Arm Bushings

1) After soaking the bolts (there are three on each side) with PB blaster remove the arm and bracket assemblies from the car noting which side they are off of.
2) Remove arms from brackets.
3) Select the proper bushing for the arms as pictured below, the center portion of the bushing is the same width as the metal sleeve in the arm.


4) Using your propane torch you need to burn the original bushings out of the arms, DO NOT do this indoors, orient the arms as pictured below. Light both sides top and bottom. The center portion and most of the rubber will eventually fall through the arm opening, after this has happened it’s necessary to remove the remaining rubber, I do this with a sandblaster, but a drill mounted flap wheel should also work well, sandblasting while the part is hot works best, don’t burn yourself .



5) Remove metal sleeve from ES bushing and insert bolt and two washers as shown.


6) Apply liberal amount of lithium grease to bushing and locate in arm sleeve as shown, add remaining washers and nut as shown.


7) Begin tightening; the bushing will be pulled into the sleeve. Once the bushing lip is completely within the sleeve as shown it’s possible to simply push it the rest of the way in by hand, it should look like this when done. Lube and re-insert sleeve into bushing.





Knuckle Bushings

1) This is the Bushing you’ll be replacing.


2) As you did insure you have the proper bushing for the Knuckle, center width should match the thickness of the knuckle as shown.


3) Using the hole saw, cut out the center of the bushing.



4) This is the tricky part, removing the metal sleeve from the knuckle, this can be done several ways, my preferred method is to use an air hammer with a chisel attachment.


Getting started with the chisel


Finished product



5) Repeat steps 5-7 of the Arm bushing install




6) Re-install on car.

Hope this is helpful, if anyone has any questions, feel free to ask. I know I’m not the best at giving directions, but hopefully the pictures get the point across...


--------------------
99 SE V6\5spd - 156 HP\157 TQ 15.166-90.84
Totaled 02/12/06

99 SVT # 1571 - 175 HP\153 TQ 14.999-91.88
Born 3/24/99 Reborn 3/18/06
Pietenpol Racing Technologies project vehicle

90 Festiva L 5spd, Blue(not for long), 103k

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RogerB
Hard-core CEG'er

Reged: 10/21/00
Posts: 3867
Loc: Wichita, KS
Re: ES Bushing How-to....finally new
#1276822 (Re: Pole120) 07/12/06 01:19 PM

Pictures are worth 1000's of words. Thanks for putting this up.

Questions:

1. Are you sure we don't need to retain the outer bushing sleeve for the knuckle?

2. I don't have an air chisel handy. I have cold chisels and hammers. Any other ideas?

TIA.

--------------------
Function before fashion.
'96 Contour SE

"Toss the Contour into a corner, and it's as easy to catch as a softball thrown by a preschooler." -Edmunds, 1998

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todras
I have no life

Reged: 05/29/00
Posts: 21197
Loc: Grand Rapids, MI
Re: ES Bushing How-to....finally new
#1276867 (Re: RogerB) 07/12/06 02:01 PM

Sweet. Goog job Polerbear.

--------------------
-'96 SE MTX 3L
-'98 SVT 1,173 of 6,535
-'05 Mazda 6s, loaded, g/f's ride
-Need a 96-00 manual on CD? PM or email me


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Auto-X FilModerator
Hard-core CEG'er

Reged: 08/11/03
Posts: 4140
Loc: Pennsylvania
Re: ES Bushing How-to....finally new
#1276969 (Re: RogerB) 07/12/06 04:12 PM

Originally posted by RogerB:


2. I don't have an air chisel handy. I have cold chisels and hammers. Any other ideas?






Jigsaw?

--------------------
-Philip Maynard
'95 Contour [71 STS | Track Whore]
'97 Miata [71 ES | Boulevard Pimp]
2006 autocross results

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Kremithefrog
I have no life

Reged: 05/14/02
Posts: 21653
Loc: Albany, Georgia
Re: ES Bushing How-to....finally new
#1277305 (Re: Pole120) 07/13/06 12:22 AM

Good how-to.

--------------------
98.5 SVT
91 Escort GT (almost sold)
96 ATX Zetec (i brake to watch you swerve)

FS: SVT rear sway bar
WTB: Very cheap beater

CEG Dragon Run - October 13-15

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Pole120
Hard-core CEG'er

Reged: 03/16/04
Posts: 4141
Loc: New Berlin, WI
Re: ES Bushing How-to....finally new
#1277321 (Re: RogerB) 07/13/06 12:49 AM

Originally posted by RogerB:


1. Are you sure we don't need to retain the outer bushing sleeve for the knuckle?

2. I don't have an air chisel handy. I have cold chisels and hammers. Any other ideas?





1) Yes, the bushing won't fit with it in there.....

2) That should work, you just need to remove the tension between the sleve and teh knuckle and it'll fall right out, a sawzall to cut a slot in the sleve would work too.

~josh

--------------------
99 SE V6\5spd - 156 HP\157 TQ 15.166-90.84
Totaled 02/12/06

99 SVT # 1571 - 175 HP\153 TQ 14.999-91.88
Born 3/24/99 Reborn 3/18/06
Pietenpol Racing Technologies project vehicle

90 Festiva L 5spd, Blue(not for long), 103k

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iluvmytour
New CEG'er

Reged: 05/17/06
Posts: 36
Loc: Is confused a place?
Re: ES Bushing How-to....finally new
#1277530 (Re: Pole120) 07/13/06 11:28 AM

How harsh is the ride? I've heard unbearable???

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Pole120
Hard-core CEG'er

Reged: 03/16/04
Posts: 4141
Loc: New Berlin, WI
Re: ES Bushing How-to....finally new
#1277585 (Re: iluvmytour) 07/13/06 01:15 PM

You've heard wrong.....

--------------------
99 SE V6\5spd - 156 HP\157 TQ 15.166-90.84
Totaled 02/12/06

99 SVT # 1571 - 175 HP\153 TQ 14.999-91.88
Born 3/24/99 Reborn 3/18/06
Pietenpol Racing Technologies project vehicle

90 Festiva L 5spd, Blue(not for long), 103k

Post Extras: Print Post Remind Me! Notify Moderator
todras
I have no life

Reged: 05/29/00
Posts: 21197
Loc: Grand Rapids, MI
Re: ES Bushing How-to....finally new
#1277798 (Re: iluvmytour) 07/13/06 05:21 PM

Originally posted by iluvmytour:
How harsh is the ride? I've heard unbearable???




From who? Isn't Josh the only one who has done this?

--------------------
-'96 SE MTX 3L
-'98 SVT 1,173 of 6,535
-'05 Mazda 6s, loaded, g/f's ride
-Need a 96-00 manual on CD? PM or email me


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Pole120
Hard-core CEG'er

Reged: 03/16/04
Posts: 4141
Loc: New Berlin, WI
Re: ES Bushing How-to....finally new
#1277805 (Re: todras) 07/13/06 05:31 PM

Originally posted by todras:
Originally posted by iluvmytour:
How harsh is the ride? I've heard unbearable???




From who? Isn't Josh the only one who has done this?




taken from the other thread....

Originally posted by Bradness:
I've said it before and I'll say it again... "Why bother?" Poly bushings used in the rr suspension cause binding and lead to harshness of the NVH type.




--------------------
99 SE V6\5spd - 156 HP\157 TQ 15.166-90.84
Totaled 02/12/06

99 SVT # 1571 - 175 HP\153 TQ 14.999-91.88
Born 3/24/99 Reborn 3/18/06
Pietenpol Racing Technologies project vehicle

90 Festiva L 5spd, Blue(not for long), 103k

Post Extras: Print Post Remind Me! Notify Moderator
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