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Discussion Starter #1
I replaced the outer one a while back with poly but never got round to the inner one because I didn't want to undo a load of bolts at the time - now I'm on a bit of a roll I'd like to do the inner one - as far as I can see I should be able to swing the axle far enough over to pop it out if both wheels are off the ground and the propshaft to diff flange bolts are removed, is there anything else that needs undoing to swing the axle far enough?
Ta
 

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I dont think you'll have enough swing with just the wheels off the ground as with the t-bar is bolted to the body, you might be lucky though. From memory I had to undo the three bolts in a triangle at each end of the t-bar/body, drop that then shift the t-bar out of the diff mount, pretty easy to do.
 

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Discussion Starter #3
Thanks Simon - I've decided to change the T bar end bushes after following Tom's thread so will have to take it all off anyway - taking the T bar off looks simple - is it?
 

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Yes it's pretty straight forward, just undo the 3 end bolts each side, it's heavier than you think though so prop it up while you undo the bolts, there should be a couple of spacers there too. The section it mounts too behind the wheel arch has a few cavities and crevices so it's a good idea to inspect and treat the metal while everything is off.

You'll need to slit the new bushes bushes and slip them in, refitting is reversal of removal as they say.
 

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Discussion Starter #5
Thanks - I fitted the poly "washers" a while back with slits and they are still there so that's fine - I've ordered the end bushes so that should mean every damn bush front and rear will have been replaced - been quite a journey - there are shims available so need to check the gap is acceptable whatever it is
 

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Joe if you remove the Tbar do you not have to set any thing back up regarding alignment etc? I just removed the end that attaches to the rear diff so that I can change the two rear rubbers.. Ive also got two new rubber spacers that I was about to cut and slot into the gaps.. (one is missing anyway but the other is still present).... Ideally I would love to remove the bar and give it a total refurb but I did not want to get into a situation where every thing was out of line?



Thanks - I fitted the poly "washers" a while back with slits and they are still there so that's fine - I've ordered the end bushes so that should mean every damn bush front and rear will have been replaced - been quite a journey - there are shims available so need to check the gap is acceptable whatever it is
 

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Discussion Starter #7
Joe if you remove the Tbar do you not have to set any thing back up regarding alignment etc? I just removed the end that attaches to the rear diff so that I can change the two rear rubbers.. Ive also got two new rubber spacers that I was about to cut and slot into the gaps.. (one is missing anyway but the other is still present).... Ideally I would love to remove the bar and give it a total refurb but I did not want to get into a situation where every thing was out of line?
The T bar is off - bit off a fiddle to get it out - don't think the bushes have ever been done as the original yellow paint was underneath the bush holders and bolts - the bush actually looks fine but the inner side might be a different matter - in two minds as to whether to change them or not but I've ordered new ones and as Tom said if you've gone this far why not, the shims fell out when I took the bar off - thick on the n/s and thin on the o/s so i'll just replace them as they are -
As far as alignment goes that was what came from the factory but considering its had a few new sills in its lifetime who knows what the alignment is like now - I'll do the basic measurement and if that's about right that'll do but if not I'll take it to my specialist tracker and see if its OK - it was last time so no reason to suspect not but |'ll need it redone as I'm fitting new track rod ends
 

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Cheers... just sent you a pm..

The T bar is off - bit off a fiddle to get it out - don't think the bushes have ever been done as the original yellow paint was underneath the bush holders and bolts - the bush actually looks fine but the inner side might be a different matter - in two minds as to whether to change them or not but I've ordered new ones and as Tom said if you've gone this far why not, the shims fell out when I took the bar off - thick on the n/s and thin on the o/s so i'll just replace them as they are -
As far as alignment goes that was what came from the factory but considering its had a few new sills in its lifetime who knows what the alignment is like now - I'll do the basic measurement and if that's about right that'll do but if not I'll take it to my specialist tracker and see if its OK - it was last time so no reason to suspect not but |'ll need it redone as I'm fitting new track rod ends
 

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Discussion Starter #9
Cheers... just sent you a pm..
sent you one back - actually just worked it out both the shims were on the n/s so that's how they'll go back - bush removal tomorrow
 

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Discussion Starter #10
Drilled and burnt the bushes out - managed to carefully cut a slot in the outer bush ring with an air saw (finally found a use for it) then whacked it with a cold chisel until created a lip which I could use to drift it out from the other side - I must have been lucky because they came out quite easily (for a bush) - new ones due to delivery tomorrow - tried loosening the track rod end lock nuts - no way were they coming off so I'm going to take it to the guy who does the tracking and get him to do it and kill two birds so to speak - nearly there
 

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Drilled and burnt the bushes out - managed to carefully cut a slot in the outer bush ring with an air saw (finally found a use for it) then whacked it with a cold chisel until created a lip which I could use to drift it out from the other side - I must have been lucky because they came out quite easily (for a bush) - new ones due to delivery tomorrow - tried loosening the track rod end lock nuts - no way were they coming off so I'm going to take it to the guy who does the tracking and get him to do it and kill two birds so to speak - nearly there
Before you took the t-bar bush housings off the t-bar, can you tell me, were the alignment marks on these actually in line with the markings on the t-bar? Mine were both about 8mm apart..

I initially thought that I would be having to reassemble them in this exact same position for some mysterious reason. However after a bit of thought, I couldn't see why alignment marks would be cast, to then be assembled un-aligned. I raised the question on the AlfaBB and have since learned that the marks should of course be aligned, as per workshop manual.

Over 40 plus years, the movement had caused a little migration between the two. Perhaps another reason for bothering to replace these, I think. Plus if you are refurbing all other bushes etc, it would be nigglingly annoying to have left these I think..
 

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Discussion Starter #12
They were a few mm out but those housings only go on one way anyway, one of the three sides is more rounded than the others so I guess as long as you know which that is then the marks are irrelevant as the T bar and housing only fit one way round - I decided to change mine as I was doing everything and was on a bit of a roll but TBH the bushes looked fine although I couldn't see the end next to the T bar - funnily enough I had a discussion with roony about the same thing. On mine the inner bush's "rings" were well and truly seized onto the T bar shafts, I assume they are meant to rotate freely so the rubber doesn't get stressed, if that's the case then I think it was definately worth doing
 

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My inner bushes were also well and truly seized onto the t-bar, or maybe not seized but certainly a good interference fit - I don't think they are supposed to swivel on the t-bar shaft when in use, that's what the rubber is for... I reckon?

I got these off by taking a flat off one side with a bench grinder when I got close to the inner shaft, they actually split along their length, which I suppose confirms that they are a tight interference fit

I think the alignment marks are there firstly so that a mechanic doesn't simply press them back on randomly, then wonder why the t-bar can't be refitted. Secondly so that when in use, there is the correct amount of preload on the rubber bush.
 

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Thank you joe90gt for this important information, guess what the next project on my S2 is?:biglaugh:
 

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Discussion Starter #16
My inner bushes were also well and truly seized onto the t-bar, or maybe not seized but certainly a good interference fit - I don't think they are supposed to swivel on the t-bar shaft when in use, that's what the rubber is for... I reckon?

I got these off by taking a flat off one side with a bench grinder when I got close to the inner shaft, they actually split along their length, which I suppose confirms that they are a tight interference fit

I think the alignment marks are there firstly so that a mechanic doesn't simply press them back on randomly, then wonder why the t-bar can't be refitted. Secondly so that when in use, there is the correct amount of preload on the rubber bush.
Just seen the BB thread and I understand why the alignment marks are there, as you say its an interference fit so they wont rotate once they are pressed onto the T bar- live and learn!
 

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Discussion Starter #17
The bushes are back on the T bar - marks aligned - the bushes went back in the housings with some help from a vice no probs but they took quite a bit of "drifting" to fit on the T bar - that's what I call an interference fit! - manged to remember to fit some spare poly washers I had as well, now to refit the T bar, could really do with a helper for some of these jobs but I've managed so far....
 

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Well Done Martin sounds like its all going to plan... I really should remove mine and post it down to yourself so that you can keep those skills sharp....:thumbup:


The bushes are back on the T bar - marks aligned - the bushes went back in the housings with some help from a vice no probs but they took quite a bit of "drifting" to fit on the T bar - that's what I call an interference fit! - manged to remember to fit some spare poly washers I had as well, now to refit the T bar, could really do with a helper for some of these jobs but I've managed so far....
 

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Discussion Starter #20
I think I've seen enough bushes to last me a lifetime but thanks for the kind offer........
 
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