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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

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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
#1277808 (Re: Pole120) 07/13/06 05:34 PM

Last I checked every model is different. You'll never know until you do it. A contour isn't purchased for floating down the freeway. I doubt you'll be able to feel those bushings back there.

--------------------
-'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
#1277814 (Re: todras) 07/13/06 05:36 PM

Originally posted by todras:
Last I checked every model is different. You'll never know until you do it. A contour isn't purchased for floating down the freeway. I doubt you'll be able to feel those bushings back there.




You cant....at least not in my experience....i installed them on my SE back in the day and didn't notice a difference in ride quality. I have them on the SVT as well...


--------------------
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
Auto-X FilModerator
Hard-core CEG'er

Reged: 08/11/03
Posts: 4140
Loc: Pennsylvania
Re: ES Bushing How-to....finally new
#1277849 (Re: Pole120) 07/13/06 06:25 PM

I thought Bradness was referring to poly ONLY in the rear - that is certainly bad because of the design of the rear suspension. If you have stock rubber in the transverse control arms, the poly in the longitudinal arm will just make that arm have more effect on the position of thw wheel.

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

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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
#1307881 (Re: Pole120) 08/28/06 05:50 PM

Just want to say a big thanks to Pole120.

Finally switched out the bushings over the weekend.

Performance? Who knows, but my clunk is gone! Woohoo!

No perceptible increase in ride harshness or noise. Of course, I'm running my rear Konis near full firm, anyway, so YMMV.

--------------------
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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tsSVT
CEG'er

Reged: 01/31/04
Posts: 218
Loc: oklahoma city
Re: ES Bushing How-to....finally new
#1307952 (Re: RogerB) 08/28/06 07:20 PM

Great how-to.The ES bushings make no noticable differance in ride or harshness.If they do make any handling differance it all depends on your driving style.

--------------------
2000 Silver SVT

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posthuman63t
Hard-core CEG'er

Reged: 07/27/04
Posts: 1746
Loc: Wisconsin
Re: ES Bushing How-to....finally new
#1308047 (Re: tsSVT) 08/28/06 09:12 PM

great how-to

--------------------
2000 Contour SVT
SF - #542 of 2150

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Thinkmoto
Hard-core CEG'er

Reged: 12/08/02
Posts: 3887
Loc: Wisconsin
Re: ES Bushing How-to....finally new
#1309195 (Re: Pole120) 08/30/06 10:58 AM

Originally posted by Pole120:
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.







It wasn't harsh in my car. Couldn't tell even eith the tubular rear control arms whatever......now if you want NVH install some ALinserts in your motor mounts Josh did you ever pull that one out of Kyles car?

Oh Josh you forgot to add make sure you don't let your tree hugging hippie neighbors see you burning out the rubber bushings

--------------------
06 GMC Sierra 2500HD Dmax/ally
06 Pontiac G6 GT
05 CRF250R
FOR SALE 06 KX65 with riding gear $2700 obo

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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
#1309241 (Re: Thinkmoto) 08/30/06 01:06 PM

Originally posted by Thinkmoto:
Josh did you ever pull that one out of Kyles car?




Yeah, he's got a full poly set in there now.

--------------------
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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Thinkmoto
Hard-core CEG'er

Reged: 12/08/02
Posts: 3887
Loc: Wisconsin
Re: ES Bushing How-to....finally new
#1310638 (Re: Pole120) 09/01/06 11:28 AM

Originally posted by Pole120:
Originally posted by Thinkmoto:
Josh did you ever pull that one out of Kyles car?




Yeah, he's got a full poly set in there now.




Put that beeotch in your car so you can feel some real vibs. Poly who needs poly [censored] sissies and your poly filled motor mounts.

--------------------
06 GMC Sierra 2500HD Dmax/ally
06 Pontiac G6 GT
05 CRF250R
FOR SALE 06 KX65 with riding gear $2700 obo

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rwea14
CEG'er

Reged: 02/25/05
Posts: 154
Loc: Merrimac, ma
Re: ES Bushing How-to....finally new
#1311000 (Re: Thinkmoto) 09/01/06 11:09 PM

can the knuckle bushing be done on the car???

--------------------
1998.5 Silver Frost SVT
#4978 of 6535
160,000 miles and still going..

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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
#1311177 (Re: rwea14) 09/02/06 09:53 AM

Originally posted by rwea14:
can the knuckle bushing be done on the car???




Sure can

--------------------
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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rwea14
CEG'er

Reged: 02/25/05
Posts: 154
Loc: Merrimac, ma
Re: ES Bushing How-to....finally new
#1311373 (Re: Pole120) 09/02/06 10:03 PM

So I have gotten about 3/4 of the way through changing my knuckle bushings on my car. I am using factory bushings that have the metal sleeves on them, my problem is this, how in the world do I get the bushing to go all the way into the knuckle? I have it within a 1/4 of inch but no matter what I do it will not go..Any ideas??

--------------------
1998.5 Silver Frost SVT
#4978 of 6535
160,000 miles and still going..

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BlackBirdRacing
Veteran CEG'er

Reged: 03/10/04
Posts: 530
Loc: Sycamore, IL
Re: ES Bushing How-to....finally new
#1311484 (Re: rwea14) 09/03/06 02:25 AM

Only thing I would add would be a part number for the ES kit...

--------------------
Originally posted by MapOfTaziFoSho:
Can u ask him to measure his shaft and compare it to your shaft?











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