ECGS clamshell bushing installation - PITA - any helpful tips?

I am in the midst of the replacement of the drivers side needle bearing in the front differential (clamshell) with the bushing made by ECGS. I already went through a struggle with bearing removal (see my other thread) that was resolved via a new extraction tool from ECGS.

Now I am struggling to install the bushing. I rented a generic installation tool and modified it with a socket to provide both a flat installation surface (aluminum plate of the rental tool) and a guiding surface (outer surface of the socket bolted to the aluminum plate). The result is a pretty nice installation tool that resembles the one sold by ECGS.

The problem is that I can't get the bushing started. The chamfer on the clamshell is very small and the chamfer on the bushing is even smaller. Even when I freeze the bushing to shrink it, I can't get the bushing to stay straight. I suspect that the OD of the bushing is larger than it needs to be, but I can't do much about that.

I have watched at least four videos on the installation, and everyone but Timmy had an easy time. I also note that in the Gen1, I have less room to work than later gen Tacomas, so I am guessing the constricted space is a factor. In his video, Timmy said that those of us working alone would struggle. He was right.

I have already spent all day repeating the same effort, re-freezing the bearing each time. After five failed attempts, I am getting frustrated.

Does anyone have any tips for someone working alone?

 

Did you get the correct bushings??

There are three different sizes . Things get boxed wrong all to often .

Have parts been swapped on your Truck at some time??

The correct tool to install makes it much easier.

 

I just measured the OD of the bearing and the bushing:
bearing 1.530" to 1.531"
bushing: 1.535" to 1.536"

As I suspected, the bushing is larger than the bearing. I understand the need to design parts for variation of vehicles in the field, but I suspect that my bushing OD is larger than it needs to be.

 

I believe I received the right bushing. See my new post with measurements. My installation tool looks very similar to the ECGS tool. Truck is stock.

 

I duno. The bushing installation was the simple part. Getting the axle out was a PITA. Assuming you tried some assembly lube?

 

Funny, I suspected that the CV axle was going to be a struggle. It took me two minutes.

I have slathered the bushing in diff oil, but not assembly lube. Would it make that big a difference from the oil?

 

Probably not. It is heavier so stayed put while I got things lined up.

 

Buy their install tool, makes life much easier.
Make sure you are installing it the correct way.

 

My install tool provides guidance, a flat bearing surface and a handle to hit, just like the installation tool sold by ECGS. I am not quite sure what advantage their tool offers. Yes, I am installing it the right way (steel lip protecting the bushing material facing outward). Thanks for your input.

 

When I did mine on my 2nd gen, the bushing went in pretty easy.
The only tip I can provide is maybe try dry ice. I worked at a place for a short time that used dry ice to shrink cylinder sleeves to press in to engine blocks. It works. And it get much colder than “regular” ice.

FWIW, I did buy their install tool.
It also has a lip that acts as a “stop”, so you don’t really risk driving the bushing in to far. Not sure it they designed it that way, but it works

Here my post on it. They probably won’t help? But maybe you’ll see something that helps?

https://www.tacomaworld.com/threads/ecgs-install-advice.712573/

https://www.tacomaworld.com/threads/ecgs-tip.720437/

 

I might need dry ice, the OD of my bushing seems larger than it needs to be (see my earlier post). The only concern I have is handling something that cold. Certainly need gloves, maybe thick gloves, and working in the constrained space is already challenging. Thanks for your input.

 

Regular gloves should be fine. Especially if you tool acts as a guide.
Yeah, it’s cold. But it won’t instantly freeze the gloves.

 

I have installed 15+ of them. Never needed to freeze. They almost never start perfectly straight. By 1/4 of the way in it will correct itself. If it starts more to the left, hit it more to the right. Hope that makes sense.

 

TBH, I can't even get it started. It starts to cam one way or the other. I have tried to start by tapping it in directly, not using the tool, to hold it in place before I put the tool on.

With the limited space, I can only make small taps. Perhaps the initial hits need to be harder, and I just can't do big hits with the stuff in the way.

It certainly seems to be larger in diameter than it should be.

 

Tom foolery aside. Bigger hammer. In the limited space available I used a 3lb hammer. More mass, less swing necessary.

 

Have you tried a dead blow hammer or a 3 lb blacksmith hammer. Either will deliver a stronger hit in limited swing space.

A 16 oz claw hammer probably isn't enough hammer.

 

Move said stuff out of the way .

You could just be fighting your self I know I tend to do that far to often

 

This is what I use from harbor freight. Short handle 3 lb hammer.

 

Good advice on the bigger hammer. I was able to get the bushing in using a 3-lb blacksmith hammer. Most of the way.

Bad news, it is protruding past the machined surface of the diff by 0.150". I believe that flush to 0.060" protrusion is ok, but it seems to be sticking out too much. I have hit it. Hard. Many times. But it seems stuck at this depth.

I measured the depth of the bearing surface in the diff and the length of the bushing before I started. It seems that getting it flush should have been possible.

 

Good tips, I installed the bushing. However, it stopped with about 0.150" protruding. I have it it quite hard, but it's not going in any further. Have you ever installed any that stuck out like this?

I Called ECGS and they said it's fine. But, TBH, I am not convinced that they know the tolerance stacks in the system. When I told them it stuck out 0.150" they said "it's fine, dude, as long as it's less 1/16". I had to tell them that 1/16" is 0.0625", less than half of the protrusion I'm seeing.