I'm working on a '96 Dodge Ram 1500 2WD and need to remove the lower control arm rubber bushing material and replace them with polyurethane? What's the easiest way to remove the rubber bushing material and save the metal outer shell so I can grease and install the lower control arm polyurethane bushings and new steel sleeves?

 

Burn them out with a propane torch. You may want to use a fan to blow the smoke away from you. It stinks! It's also a trick used to remove ones you can't get out. Burn the rubber off then use a hack saw or die grinder to cut the metal.

 

Unfortunately yeah, FIRE FIRE!! seems the best way. I'd wear a mask (of course you should everyday anyway to show what a good person you are -- especially when driving alone in your Subaru) and use a fan as suggested.

I've drilled them before but it takes one million holes and even then is a fight.

Let us know how it goes!!

 

Thanks much for the replies. Sounds like I'm going to have a BBQ... In your experience, can I just use the torch to start burning the rubber out of the bushing metal shells and the melting of the bushings will continue without keeping the flame going on the bushing or must I sit there for some time keeping the torch on the rubber bushing to keep the fire and melting going?

 

Press them out, Then heat the outside metal all around. The center will fall out with out having to melt all the rubber. Then do the same to the center to separate it from the rubber. Oh and when you do this have something on the floor to catch the molten rubber. After it dries it not easy getting off concrete. Wouldn't hurt to have a spray bottle of water either if things get out of hand.

 

The pressed-in lower bushing outer metal shell is relatively open in the arm. Can I just heat the open area of the bushing's outer metal shell to achieve the same result without having to press it out (I could press it out, but was curious if I really had to press the bushing out or not)? BTW, great thought about keeping the concrete from being stained and having water handy.

 

I think you can do it however. I'd leave the outer sleeve in the arm because pressing just that back in might be difficult without folding an edge.

I think it's crappy that poly bushing manufacturers require the outer sleeve remain. Honestly all I ever do is get EVERYTHING out of the bore and make bushings. This is first day Machining 101 with a lathe and HDPE or acetal stock is readily available and inexpensive. I reuse the inner, hardened sleeve

 

I have found that its actually EASIER to get the rubber, and inner sleeve out, leaving the outer sleeve in place... I don't care what I do to the rubber, but, the mere act of removing the outer sleeve has a tendency to rearrange it beyond usefulness.

 

Thanks to all for the thoughts on this job. I'll try to heating up the bushing outer sleeve in the arm and see if I can get the rubber bushing and inner sleeve out.

Already got the upper control arm bushings replaced with poly, but Energy Suspensions provided new outer sleeves for the uppers which made that job relatively easy.

 

Heat (propane torch) for the win! Placed a pail of water under an old stripped down 727 case I had laying around and placed the lower control arm with the large rubber bushing end facing down over the hole in the back of the transmission case where the sprag sits. Heated up the outer shell (while still in the lower control arm) holding the rubber bushing until I could hear the rubber inside of the shell crackling and the top of the rubber bushing burning. I stopped heating the bushing and use an air hammer to gently push out the rubber bushing and inner metal sleeve. Worked like a charm and much easier than I thought it would be.

Thanks again to all with your ideas as to how to tackle this job. Really appreciate it.