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I just built one a few weeks ago and pressed out a really nasty bushing.
I used 1/2 all thread and had an older 240 lugnut welded on one end to basically make it a bolt. Home Depot didn't stock the correct length bolt, but had everything else for a total cost of $13.xx.
My bushing was trashed, so the little metal sleeve that the bolt passes through in the middle of the bushing was off center. When I ran the bolt through the bushing, the bolt was pulled off center due to the bushing sleeve, so we had to drive the metal sleeve out with a large c-clamp meant for ball joints (think that's the normal use of the tool).
Make sure you press against the smaller end of the bushing (it's tapered, only goes out one way). Once I had it on the right way, it pressed out easily.
Next problem was that I ground down the bushing pusher plug too much, so it wouldn't stay centered on the bigger end of the new bushing sleeve. Couldn't press the new bushing in w/o the plug slipping off center. So a piece of 3/16" steel plate was torched to make a hole in the center, and that was used like a giant washer to go up against the bushing. Worked great.
The half-round piece used to support the flanges on the axle had to be ground down to fit (this is mentioned in the directions, measures 2.125", needs to be ~2").
I did this job on a lift. It would suck to do it on your back in the driveway, but it's possible. Didn't require any air/power tools, but they make disassembly easy.
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forums.turbobricks.com
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