This is part 2 and will explain the actual bushing removal and installation. Part 1 covered removal of the spring plates (and torsion bars) from the car.
See part 1 here Part 3 will cover installation into the car
Click for part 3
Click any picture for a larger view.
With the spring plates on the bench, the deterioration of the factory rubber bushings is obvious. The factory rubber cold flows over time from the weight of the vehicle such that even low mileage bushings deform after 15 years or so. In this case the car is 18 years old with about 80k miles, fairly fresh as 944s go.
These pictures tell the tale; the digital readout is partly obscured but you can read the scale. One side of the bushing is 16mm the other is 20.22mm. It is supposed to be round / equal thickness. These measures are taken on the bench, but with the weight of the vehicle in the difference would be even greater.
Next step is to remove the bushings. The bushings are vulcanized to the spring plates and they are very secure. Removal is knowned to be a very difficult job, and if done incorrectly it is a difficult job.
Not to worry, I’ve done this many times and have developed a technique that is easy. Follow my instructions here and you will have it done in no time. Secure the spring plate in a bench vice. Use a propane torch to heat the metal tube of the plate from the inside. Your goal is to get the metal hot enough to melt the contacting rubber. Heat it for several minutes.
While it is still hot, work a flat blade screwdriver between the rubber and the metal tube. Work all the way around to separate the rubber. Use a razor knife to separate the rubber from the flat part of the plate. The bushing can now be easily pried off.
This will remove 90%+ of the rubber in one big donut. Next use a razor knife to cut off remaining large chunks. Cut away the thin layer that covers the tube portion of the spring plate. Small bits of rubber will remain. These can be removed easily with some medium sandpaper.
Be sure to get the tube portion of the spring plate very clean, any residual rubber here would interfere with the fit of the new bushings.
Next I recommend having the plates re-plated. Get them plated along with the hardware with yellow zinc dichromate. Shop around and you can get this done for $40-$50, well worth it. You may have some other parts you’d like to throw in the batch too.
Not only do the plates look like new, the acid bath used in the process will clean off any remaining rubber bits. Don’t rely too much on this for rubber removal though, give the plater clean parts.
This really gives the project a finished appearance. Do it once, do it right and be proud.