Re-bush or replace?

[spannerrash]

I'm just curious as to other owners experience / opinion on Re-bushing audi suspension control arms.

I've never really felt the need to Re-bush any aluminium suspension components up until this point, I generally just replace the whole thing. As control arms are getting harder to get hold of for my D2 rear end I thought I'd give it a go.

I bought some second hand rear control arms and some Febest bushes to experiment with. I have a 6t press and variety of pressing tools to use so was expecting it to be pretty streight forward.

I couldn't have been more wrong......

I managed to get the 6 bushes out of the 2 rear control arms but it was a real pain and took ages. I have, as yet, not managed to get a new one back in without destroying it. No mater how much I clean the arms and lubricate the bushes, they always seem to jam up 3/4 or so of the way through and then the press just distorts them.

I know it can be particularly difficult pressing into aluminium as things seem to pick up on the ally but what am I doing wrong here? Or is re-bushing just generally not a good idea?

[MikkiJayne]

I re-bush the rear arms a lot. They have to be destroyed to get them out, but then they all do. I made a tool to push them back in though - its a cup shaped thing which presses on the outside flange and the centre at the same time so it doesn't try and push the rubber through the flange. I put them in with a bench vice since I don't have a press, and always lubricate them with WD40 or similar beforehand.

[spannerrash]

I actually have the official VAG 3350/2 tool which I guess is similar to what you are using. I've been using it in a press rather than with the bolt and cup that it comes with. I thought the press might be easier.

One thing I have just noticed is that the Febest bushes are slightly different in that the outside diameter is slightly larger. Only 1/2 mm or so. Would that be enough to cause them to jam?

I have an original bush so I'll give that a try in the vice tomorrow. I'll let you know how I get on.

[MikkiJayne]

The original alloy bushes are larger than the hole too. You can see them necking down as they go in. The single-piece steel one isn't though obviously. Thats just a very tight interference fit.

3350/2 isn't quite what I've made - that looks like it presses on the outer flange only whereas mine is a lot shallower so it also touches the inner bushing, although doesn't put any significant force on it. Theoretically they ought to achieve the same result.

Sometimes tapping the arm with a hammer around where the bushing goes in helps to release the stiction and it jumps in a little further while still under pressure from the vice.

I've not really had any problems pushing them in tbh - getting them out is more of an ordeal, especially the steel one.

[spannerrash]

Sorted
Got rid of the press, used a combination of the vice and the vag tool. All went together easily with no drama at all.

I don't think my press is pushing squarely. It's only a cheap thing.

[MikkiJayne]

Good news I've never done the upper arm - there never seems to be any appreciable wear on those.

Were the bushes available from Audi or are they aftermarket?