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replacing 240 rear end bushings 200

I am in the process of installing front and rear IPD replacement bushings on my 1975 Volvo 245 (original owner). The front went well but I have encountered several problems/questions on the rear.
1 - Track rod bushing on passenger side - This bushing has two slots and I need to know the proper orientation of the slots. This one was replaced previously (in 1989) and I was similarly confused at that time so I'm not sure it was installed correctly. My original Volvo workshop manual says "the bushing slots should point according to the figure below" but the figure shows no orientation indications that I can decipher. Can some one help with the proper alignment?
2 - Torque rod bushings - Similar orientation issue as the track rod bushing above. In this case the manual does say to align so that the "flat sides are parallel to the rod". Clear enough, but after installing them this way on the driver's side rod I'm almost certain that the old ones were rotated 90-degrees from this (never changed previously). I should have paid more attention prior to their removal but I will confirm this when I remove the passenger side rod. If it turns out that its flats are 90-degrees to the rod, what is correct - the manual or the original installation?
3 - Large rear trailing arm bushing - Last, but not least, the "monster". Even though the originals are not obviously shot, I hoped to change them anyway. I wanted to do this myself and if possible also avoid the cost of the special tool designed for this purpose. So, to brace the axle brackets I wedged four bolts between them and achieved a pretty tight fit. I then inserted a 12-inch length of 1/2" "all-thread" through some very heavy large washers on the "pushing" side and a 5" pipe nipple on the receiving side. The pipe nipple is just larger than the O.D of the bushing so that it can consume it. On the "pushing" side the washers would be too large to go through the bracket opening but I figured I would get the bushing to start moving the first 1/4" inch with them and then replace them with an appropriate sized socket as a drift when it came time to enter the bracket opening. The set-up looked good but after torquing down on the nut the all-thread snapped in two! And the bushing gave no hint that it had even begun to budge! Perhaps it's just a case that the all-thread I used wasn"t up to the task (purchased at a local auto store / 20-threads per inch / 1/2" diameter / marked "S.A.E." but no indication as to grade). Comments or hints from any one who has tried this? Should I try again or am I just wasting my time and should part with the $165 bucks for the tool?








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    replacing 240 rear end bushings 200

    You will definitely need a tool to install the bushing. Volvo, ipd or one of the homemade versions will work.
    I recently did all the bushings on my '83 and my mechanic gave me a nice shortcut for removal. You need to have an air system. Take an air chisel and cut directly into the bushing shell. You should be able to slit the shell from end to end. Collapse it a little and you can tap the remains out with a hammer. There are no shortcuts I know of for installation.

    Skip
    '93 850GLT
    '89 765T
    '83 242TI Flathood








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    replacing 240 rear end bushings 200

    Track rod bushing. I can't help you there. I recently replaced all my rear bushings but the one for the right hand side of the track rod was solid rubber. Someone here will know.
    Torque rods. Can't help you there either. I replaced mine with the later type. I can't remember the position the "hour glass" shaped ones. Someone here will also know this one.
    Trailing arm rear bushings. See this if you haven't already. It really works.


    --
    1980 240 DL








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    replacing 240 rear end bushings 200

    I can't remember the orientation of your #1 and #2 question but the Trailing arms..
    You can cut them out and the new ones will go in easier after cleaning and greasing up the parts. The Trailing arm bushings also have a direction. The hole for the bolt is not centered in the bushing.

    --
    '75 Jeep CJ5 345Hp ChevyPwr and two motorcycles: it wasn't Volvos safety , it was Longevity that sold me








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      replacing 240 rear end bushings 200

      all these volvo bushings that I have ever worked on have gone in the way you DON
      T think they should. that is, for the trailing arm, for example---you would think that since the axel is pushing the car, that the firm, solid part of the bushing would go fore-aft, to take the punishment of driving the car, but it doesn't. instead, it goes in in such a way the the action of driving the axel to push the car has the greatest chance of deflecting the bushing. They all go in "as soft as possible" the rear trailing arm bushing has "down" marks, and the openings around the hourglass end up front and back, with solid rubber up and down (can soemone else verify this--I just did it, but don't want to be wrong). When you dump the clutch, and the axel surges forward to push the car, this bushing will deflect more in this position than if it were installed with the rubber fore-aft. Also, the bushing is not round, so the down mark may have something to do with that, also.

      Based upon the above, I would install the panhard (track) rod bushings with the openigns side-to-side.

      for the support (torque) rods, call volvo demolishers and try to simply get rods with solid bushings. there were two types, solid and hourglass. here in boulder, co, the brick fixers toss all rods with the hourglasses, and sell used solid bushed rods for $25 each. If you will install hourglass bushings, put the openings for-aft

      Control arm bushings have three "hourglass" holes, so follow the instructions in the manual. There used to be bias and radial types depending on what tires you run. I assume there are no more bias type CA bushings anymore.

      make a press from 2" pipe fittings for the rear trailing arms. there are links on the web, search for "trailing arm bushing volvo" and i bet you will find it. I broke a couple bolts doing this until I was more carefull about jig alignment--it must be rigged so that the bushing can enter the jig. mine caught a couple times and not knowing how much force was necessary, I broke some grade-2 bolts. when it is all lined up well, a 1/2-13 grade 2 should just do it without stretching, galling, breaking. you could just use a wood block to keep the "ears" spread, and a pipe coupling and sockets (if you got big ones) to press it in/out. i used a 2" electrical conduit threaded (not tapered) coupling and two 2" plugs with holes drilled in them. one plug needs to have the threads removed via lathe or grinding.







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