i made a bushing tool a while ago (see original post http://www.brickboard.com/RWD/index.htm?id=1215068). only yesterday did i have the opportunity to put it to use on my own 240. even though i was replacing the bushings with poly ones, i still pushed them out to get the shells burned clean. the tool worked very well with only a few quirks. here are some observations:

1) the tool needs to be centered on the bushing when in use. however, bushings in bad shapes, as mine were, often have the center sleeves sagging too low for the tool to center. one might need to get the sleeves out first or do some creative rubber bending.

2) if the rubber bushings are being replaced by poly ones, the tool can be used to push the poly blocks into their shells (after pushing the shells back on) and pushing the inner sleeve into the bushings. beat all that grease!

3) it might be useful to have a few spare parts. for the tool i made, an additional, shortened version of part B would make pushing the bushing in a bit easier (my hex plug cannot thread into part B very deep). a 7-1/2" long screw and a 7" one would be nice too (for pushing other things into the shell).

4) drilling the 1/2" dia hole in part A on a mill will yield a hole with a bit too little tolerance. if i were to do it again, i'd make the hole slightly (like a few thousandths--i'd say 3 max) bigger by drilling through repeatedly/sanding/taper-reaming/filing/etc. this makes dropping the screw in for push-in much easier.

the rear trailing arm bushing wasn't too eventful other than one bushing shell being almost too rusty to hold its shape. i might need to replace that shell and its poly bushings again some time later. the front trailing arm bushing gave us more trouble. i had to machine some pieces to help pushing it out.
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'91 240SE Wagon