Clutch Release Shaft Bushing tool

Nick Bernier

Nick Bernier

Member
Hi All,
I'm trying to replace the two clutch release shaft bushings (1940, 40-7508). Third Gen has a tool to drive the old ones out, and new ones in, but they're out of stock. I don't want to booger things up. Anyone have a good tip on how to do it without the magic tool?
Thanks,
Nick
 

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I been using a generic bushing driver set for years with excellent results. You can get these cheaply from either Amazon or Harbor Freight.
 
Last edited:
Nick Bernier said:
Hi All,
I'm trying to replace the two clutch release shaft bushings (1940, 40-7508). Third Gen has a tool to drive the old ones out, and new ones in, but they're out of stock. I don't want to booger things up. Anyone have a good tip on how to do it without the magic tool?
Thanks,
Nick
Click to expand...
539007
 
You'll probably find that you'll need to ream or hone the IDs of those once they're installed. You can use a basic brake cylinder hone to get the job done.

I made a pilot on my lathe - that picks up the ID as well. These split bushings like to collapse and then the ends will overlap . . . then you start all over again!
 
I purchase one of these drivers a while back from Third Gen. Here are the dimensions of the driver as well as the bushing. Maybe you can find a driver local that would work. Hope this helps.
Nate
 

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Check the OD of sockets you have in your tool box. One might clear the bore and fit the OD of the bushing so you can tap it out. If you have access to a lathe you could "turn" a "shouldered" tool with an smaller OD to fit inside the bushing and a larger OD to fit the case. Or, buy a 7/8 bolt, saw off the threaded part and use the shank, square the end and use it as a driver after filing it down to clear the bore.
 
Last time I did one with a driver I put a hose clamp around the outside to keep it from collapsing the split bushing. worked great.
 
Harbor Freight has bushing driver kit which is inexpensive and fits many bushings. It can be used to install or extract. I like to use threaded rod and nuts to press the bushing drivers, instead of using a hammer
 
Good news is the bushing tool arrived. Bad news is I still can't bust them loose. Tried pressing them out with a clamp and tried pounding them out with a hammer. The too actually started spreading one of the bushings out, getting the tool stuck in it for a bit. What to try next?? Heat? I only have a propane torch. Penetrating oil? Should I try to just mangle them with a chisel? Other ideas??
Thanks,
Nick
 
You can use an old slender tipped screwdriver….one that you’ve already pounded on before, and work the tip against the edges of the old bushing. Drive down to force the bushing inward. Generally, then you can finish driving it out with a large brass drift punch. Worse case scenario, you fit a hacksaw blade through the bore and carefully cut into the brass enough to let it be driven out.
 
Nick, Mangle away my friend. You aren't trying to save the old bushings.

A little FYI when installing the new bushings: Sand a slight leading-edge bevel on the OD of the bushing so it just barely starts in the hole.
 
Try the hose clamp around the bushing. It works just like the piston ring compressor as you drive the bushing in. I ruined two before I tried the clamp.
 
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