Pilot bushing removal is no fun

[PanhandleShantyman]

Ok gents, time for an update on the stuck pilot bushing of doom:

I bought the grease gun fitting Alloyvert mentioned, but this also didn't budge my bushing, pump as hard as I might.

So then I tapped it and ran a bolt through it to push it out, like RichardJ suggested. The threads in the soft bronze just stripped right out on the bolt, and again the bushing would not move!

So then I left the truck in "timeout" on the jackstands in my garage while I went to Las Vegas on vacation.

When I got back I got a tungsten carbide cutter bit for the ol' Dremel tool and cut through the bushing. Once I did that, it came out real easy with the Harbor Freight puller. (in my rage I cut too deep and actually gouged a pretty decent cut through the bushing and into the crankshaft....oops...I'm sure that will be fine...)

I dunno what the heck was up with this bushing. I think I bought $200 of tools and tried every dang trick in the book to extract this thing, all of which failed to budge it a single hair:
1: Harbor Freight /Autozone pilot bushing puller. FAILED
2: Grease and bread method with extension rod mandrel. FAILED
3: Grease and bread method with custom fit oak mandrel. FAILED
4: Slide hammer. FAILED
5: Tap-in style grease fitting . FAILED
6: Running a bolt through tapped bushing FAILED
7: physical destruction of the cursed bushing with a tungsten carbide cutter: SUCCESS

I think I'll use the remains of it as a doorstop. As hard as the thing is to move, that should make my house burglar-proof.

Anyway thanks everybody for all the help!

[Getter-Done]

Glad to hear you Got it out .

[typerr]

I hear you brother. When I did my 3-speed to T-5 swap I got the bright idea to replace the pilot bushing. I also bought several of the tools listed above. I finally resorted to using a small chisel to chop the bushing out in bits. Crank was left pristine surprisingly. All was done laying on my back with the truck on jack stands. Hopefully never again...

[CAMAROBOY68SS]

yeah I had a hell of time as well getting my old one out when I did the tremec swap. Took a tiny saw, then a chisel and a hammer to knock it out. The puller never worked and neither did the old bread or bar soap trick. The C10 has been the only one to fight me, guess they meant it when the old tag line said "like a rock" lol.

[Luke87gt]

I am not looking forward to this job after reading this thread lol

[Accelo]

It's likely an aftermarket replacement that was installed.
Remember, you are now the quality control person.
I have the tools to measure the interference fit; many have been way out. One was .008 oversize. An eight-pound hammer would not have gotten it to fit the bore.
One was so tight after I managed to get it installed, and then the transmission pilot would no longer fit in the bore. It collapsed substantially during the installation process.
I now measure all the replacement bushings. I would recommend you do it also.
Even a dial calipers it better than nothing.

[RichardJ]

>>So then I tapped it and ran a bolt through it to push it out, like RichardJ suggested. The threads in the soft bronze just stripped right out on the bolt, <<

NO, I NEVER SAID THAT.

You may have used too small of a tap. The tap bottoms out and does the pushing, all in one single, simple operation.

[jjzepplin]

A little late but maybe for the next guy. I always used an input shaft from a Muncie and the grease. Thickest I could find. Always popped right out. Great for aligning the new clutch too. Then leave the trans in any gear when installing and and old yoke from a driveshaft in the tail of the trans to turn the inner gears and that baby slides right in all by yourself.

[72c20customcamper]

Originally Posted by Accelo

It's likely an aftermarket replacement that was installed.
Remember, you are now the quality control person.
I have the tools to measure the interference fit; many have been way out. One was .008 oversize. An eight-pound hammer would not have gotten it to fit the bore.
One was so tight after I managed to get it installed, and then the transmission pilot would no longer fit in the bore. It collapsed substantially during the installation process.
I now measure all the replacement bushings. I would recommend you do it also.
Even a dial calipers it better than nothing.

I had one do this when I rebuilt the Super t-10 in my AMX . I won’t use the supplied pilot bearing with the clutch . Trans shaft would not go in bought a USA made one fit was perfect.