If you've ever done a proper clutch replacement, then you've wrestled with removing the pilot pushing via one means or another-here are three of the most common ways it's done. While we've never had any luck using our pilot bushing removal tool (lead photo), the hydraulic grease trick has never let us down. Here are some choices. Pick your poison.
The hydraulic method is simple...
The hydraulic method is simple if you've got the right clutch alignment tool that fits tightly inside the bore of your pilot bushing. First, pack the cavity behind the bushing with grease.
With a soft-face mallet or...
With a soft-face mallet or dead-blow hammer, gently tap the tool into the pilot bushing bore. Some grease will ooze out past the tool. Just keep repacking to keep the bore full. Eventually, the bushing will work its way out. We've never had this method fail us, but if it doesn't work for you, it may be time to break out the chisel.
To chisel out a pilot bushing,...
To chisel out a pilot bushing, first make a groove nearly the entire depth of the bushing with a carbide bit or other rotary tool. Don't go all the way through because you don't want to damage the crank surface.
Here's what you should wind...
Here's what you should wind up with once you're done with the rotary tool. There's enough bushing material to protect the crank surface, but enough has been removed that a chisel will easily split it.
Carefully place the chisel...
Carefully place the chisel in the groove and give it a good, firm whack with a hammer. Go slowly and check after each hammer strike.
Once the bushing cracks, the...
Once the bushing cracks, the pressure holding it in the bore is relieved. It should just come right out with no problem.
A good method for installing...
A good method for installing a new pilot bushing is to lop off the end of a broom handle. The soft wood of the handle won't distort the bronze bushing and will allow easy installation of the transmission input shaft.