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1994 Chevy C1500 Buildup - Bad-Ass Bushings

 
1994 Custom Chevy Truck Suspension Bushings Remove Cotter Pins
The truck was placed on a... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Cotter Pins
The truck was placed on a lift, and everything that is hooked to the spindle was removed. Here, Nate removed the cotter pins with a pair of side cutters.
1994 Custom Chevy Truck Suspension Bushings Remove Ball Joints
Billy Harill, the other technician,... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Ball Joints
Billy Harill, the other technician, popped the ball joints with a few good whacks of the hammer.
1994 Custom Chevy Truck Suspension Bushings Remove Spring
With all the joints freed,... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Spring
With all the joints freed, Billy removed the DJM lowering spring. Because this is a drop spring, we didn't need to use a spring compressor, but if you are working a stock truck, be careful because those springs are under a lot of pressure and can fly out with devastating results.
1994 Custom Chevy Truck Suspension Bushings Remove Control Arm
After removing the two bolts... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Control Arm
After removing the two bolts with a 21mm socket and 15/16 wrench, Billy and Nate wrestled the control arm out.
1994 Custom Chevy Truck Suspension Bushings Remove Insert
Over at the press, which is... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Insert
Over at the press, which is not a necessity but sure makes the job easier, Billy pushed out the steel insert that was in the center of the factory bushing.
1994 Custom Chevy Truck Suspension Bushings Remove Insert
Don't try and push everything... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Insert
Don't try and push everything out in one shot. Get the insert out first, then remove the rubber. He used a lot of WD40 and a bolt to push on the insert.
1994 Custom Chevy Truck Suspension Bushings Inserts Removed
These are the inserts that... 
   
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1994 Custom Chevy Truck Suspension Bushings Inserts Removed
These are the inserts that were pushed out. They won't be reused, but it makes the job easier to do if you take out the bushing, piece by piece.
1994 Custom Chevy Truck Suspension Bushings Remove Rubber Bushing
Now for the rubber, Billy... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Rubber Bushing
Now for the rubber, Billy forced a flat-head screwdriver down the edge of the rubber so he could load it up with lube.
1994 Custom Chevy Truck Suspension Bushings Screwdriver Remove Bushings
Once he had it fully lubed,... 
   
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1994 Custom Chevy Truck Suspension Bushings Screwdriver Remove Bushings
Once he had it fully lubed, he pushed up on the handle of the screwdriver, which pulled out the bushing.
1994 Custom Chevy Truck Suspension Bushings Apply Lube
After a good cleaning, the... 
   
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1994 Custom Chevy Truck Suspension Bushings Apply Lube
After a good cleaning, the now-empty hole was given a liberal coating of Energy's Formula 5 lube. This stuff is pretty sticky, so keep a few rags on hand. Billy said, "You can't use too much of this stuff, because you can always wipe off the excess later."
1994 Custom Chevy Truck Suspension Bushings Insert New Bushings
The polyurethane bushing can... 
   
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1994 Custom Chevy Truck Suspension Bushings Insert New Bushings
The polyurethane bushing can be pushed in by hand...
1994 Custom Chevy Truck Suspension Bushings New Bushing Insert
1994 Custom Chevy Truck Suspension Bushings Press New Bushing Insert
...and then you will need... 
   
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1994 Custom Chevy Truck Suspension Bushings Press New Bushing Insert
...and then you will need the press or a vise to push in the new insert.
1994 Custom Chevy Truck Suspension Bushings Old Ball Joint Boots
Can you tell this truck needs... 
   
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1994 Custom Chevy Truck Suspension Bushings Old Ball Joint Boots
Can you tell this truck needs some work? The ball joint boots were trashed on all four control arms. Thankfully, Energy supplies these in the Master Set. Ripped or torn boots will let all of the grease leak out of the joint and increase the chance of failure.
1994 Custom Chevy Truck Suspension Bushings Remove Old Boots
All you need is a screwdriver... 
   
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1994 Custom Chevy Truck Suspension Bushings Remove Old Boots
All you need is a screwdriver to pop off the factory boot.
1994 Custom Chevy Truck Suspension Bushings New Boots
The new boot will pop on with... 
   
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1994 Custom Chevy Truck Suspension Bushings New Boots
The new boot will pop on with minimal pressure, but just make sure you clean off the area around it beforehand. You don't want to seal in any dirt.
1994 Custom Chevy Truck Suspension Bushings Control Arm Washer
The factory washer that is... 
   
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1994 Custom Chevy Truck Suspension Bushings Control Arm Washer
The factory washer that is used for the control arm bolts has a small ridge built in it, so when it is tightened it pushes in on the cup to lock down the insert of the bushing and keeps it from rotating.
1994 Custom Chevy Truck Suspension Bushings Control Arm Prep
Before you install the control... 
   
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1994 Custom Chevy Truck Suspension Bushings Control Arm Prep
Before you install the control arm, use a file to knock down the inside of the cup. This will help you a lot when it's time to reinstall your arm.

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