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Rear Suspension Knuckle Bushing - 4 Ways to Remove/Replace - Chevy Venture AWD

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Hartz Homestead

Some valuable tips we learned for removing and replacing rear suspension knuckle bushings, which can be a challenge to press out and back in. Loose bushings can result in uneven tire wear due to poor alignment. These techniques can be used with knuckle bushings on any vehicle.
Many thanks to Al for helping with this project, and having many of the tools we needed.
This particular van is a 2002 Chevy Venture, AWD. The same bushing also fits Chevrolet Uplander; Pontiac Montana & Aztec; Buick Rendezvous & Terraza; Olds Silhouette; Saturn Relay; and Cadillac Allante, DeVille, Eldorado & Seville.

The methods I show are:
1. Using a Ball Joint Press Tool, which you can rent often for free at auto parts stores;
2. Putting a bolt through the middle of the bushing the key is having spacers the right size to push the bushing out from one side, while pressing on the knuckle from the other side. You'll need a fine thread grade 8 bolt about 1/2" x 6" depending on your bushing and spacers. An air impact wrench is recommended if you have one. Heating up the knuckle with 2 torches can also help.
3. Cut the bushing from the inside with a reciprocating saw or hacksaw. This works best if you can drive the center piece out first, otherwise you have to cut through it too. Stop right at the knuckle, and then press or drive out the pieces.
4. Remove the entire knuckle and have a machine shop press out the old bushing and press in a new one.

To install the new bushing, you can often hammer it in with the installation tool, which is simply a ring the right diameter to press the bushing in. It may help to put the bushing in the freezer or a bucket of ice for an hour first. You could also press it in with either method 1 or 2, but might need different diameter spacers to press in than out.

You may need 2 jacks, one for the vehicle, and one for the knuckle, and may need to remove the brake caliper, rotor and parking brake cable. Hang the caliper aside with an S wire so as not to stress the brake line.
We installed Moog K200840 bushings, but found the new ones were a few thousandths of an inch bigger than the old ones, so had to sand out the knuckle to get them to fit. You might want to go with OEM parts.

posted by Darmbein7l