Sunday, January 30, 2011

AE86 Prothane Bushings Fitment

Last weekend was allocated to get those Prothane bushings installed. After seeing the whole process, bushing fitments are clearly not for those without the proper tools. It should take you a whole day to put the bushings both on the front and rear side, swearing and yelling from working on 20+ years old sticky parts included.

Just a quick reminder, i am using Prothane Bushing Total kit for AE86 on my Charmant. Having the exact same suspension parts as her tofu delivering cousin (damn i love this car!), nearly all of the bushings from the kit can be used. The only difference between AE86 and Charmant is the rear sway bar (or the lack of it on the Daihatsu trim so you'll be left with the bushings for these unused).

Most of the fitment work is straightforward. You pull the part out, drill/cut/burn/press and curse the old bushings away, put the new ones in and reinstall. An exception was found on one end of the panhard or lateral rod from the RR Track Arm Kit (#18-1205). One of the ends have a non-split bushing. You may need to get help from a machine shop to fit it unharmed.
Took the mechanic working on my fitment a handful of tries before finally succeeded. The mechanic was using simple tools and a last-minute pressing machine so don't blame him for the tries. It will be tempting to split the bushing to make it easier but don't. There's only one non-split bushing so it won't hurt to pay extra and get some pro help on it.

Here's the emergency pressing machine the workshop used.
A ladder-shaped frame and a car jack is all. Mind that they didn't use any drill or torch to get the bushing out. A handsaw, hammer and that press machine were the main tools used. Here's the ghetto rig pushing an old bushing out of a front control arm.
Here's the mechanic finishing the front end. The arrows point to the location for the frond end bushings. If it's too hard to see, better diagrams are below.
I got help a lot on this one from my friend Yohann. He detailed which part goes where on this post. See the comments section. So, credits to him also for these diagram i made. Hopefully you will meet less problem as me with these diagrams.

On above diagram, the Sway Bar Bushing on the kit (19-1120) comes with the brackets also. However, i chose to keep the old brackets. The bolt holes for the new brackets were slotted while the old ones were round. I find that the round shape would keep the brackets in place better.

For the rear end, there's no sway bar on Charmant so you'll be left with the end links (#18-401) and bushings (#18-1130) unused. You can sell these to get some money back or retrofit an AE86 sway bar and use them.

Driving the car with new bushings gave a whole different impression. You can "feel" the road better, for lack of a better word, and the car is less wobbly. I'd definitely suggest you do the same upgrade. It'll be worth every penny. Proof? Here's some. New vs old front sway bar end link, can you say beefy?
Or here's a more basic reason..
Healthy strut rod bushings vs 20 years old burger. You simply can't expect good drivability from old and worn out suspension bushings.

1 comment:

  1. Man what a great post! Now I'm tempted to get a Prothane bushings as well!

    ReplyDelete