Rear Cross-Member Bushing: Service and Repair

Suspension Subframe Bush

Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.

1. Remove suspension subframe from vehicle.





2. Position special tool 204-116-02 on press-bed with the recesses uppermost.





3. Remove nut and washer from tool.
- Position special tool 204-116-06 on bush with recesses accommodating the bush rebound stops.
- Install washer and nut on tool, but do not tighten nut at this stage.





4. Invert subframe and position assembly on special tool 204-116-02, with subframe located in the recess.

CAUTION: Ensure special tool 204-116-06 is correctly aligned and does not contact the bush housing bore.





5. Remove bush from subframe.
- Align assembly with the press-ram.
- Operate press to remove bush.

6. Remove bush from special tool and discard bush.

7. Thoroughly clean the bush-housing bore.

Installation

1. Use a coarse grade emery cloth to roughen the bush-housing bore, and mating surface of the bush.

2. Using an air line, remove residual dust from bush and housing mating surfaces.

3. Clean the bush-housing bore and bush with cleaning solvent (SPB3 Solvent 30) or equivalent.

4. Invert suspension subframe.





5. Mark bush position on sub-frame.
- Stretch a length of thin cord across the center line of each bush location.
- Below the string, place two pieces of masking tape diametrically opposite on the bore periphery.
- Mark string position on the masking tape.

NOTE: New bushes are bonded in position using a rapid drying adhesive. Application of this adhesive and fitting of the bush must be completed within 3 minutes. It is therefore strongly recommended that the procedure is rehearsed to ensure it can be completed within that period.





6. Position subframe on a hydraulic-press.
- Position special tool 204-116-02 on press-bed, with recesses uppermost.
- Position subframe on top of tool.





7. Apply "Alphabond Rapid 101" epoxy adhesive to the shaded area of the bush (as shown), and corresponding area of the bush-housing bore.





CAUTION: Bush alignment error must not exceed 5 degrees.

8. Aligning bush with subframe.
- Position bush with large single void facing forward.
- Align small void centers with masking tape markers.





9. Install bush in housing.
- Position a steel plate over the bush, ensuring the plate is large enough to cover the rubber flange.
- Operate the press to install the bush.





10. Ensure bush is fully seated in subframe.
- The clearance between the bush flange and subframe must not exceed 1.5 mm.

11. Ensure bush is aligned correctly in subframe as detailed in Step 8 or 9 as appropriate.

12. Wipe off excess adhesive from subframe and bush, and remove masking tape.

NOTE: Allow adhesive at least 30 minutes to cure, before installing subframe on vehicle.

13. Install suspension subframe on vehicle.