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I guess I'll break out my Dremel tool and start sanding. How tight do they need to be? Are the bushings supposed to be greased?
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They need to fit nice & tight, they mustn't just slide in. What you will find is the inside of the metal where the outside of the bush contacts is very rough with casing imperfections. Smooth them down until the bush is a tight fit with a coating of bushing (silicone) grease.