Removing and refitting poly bushes

This is a guide to removal and refitting of bushes on a Mk1. It's not particularly difficult, but can be very frustrating at times.

There are 8 front bushes in total
4 wishbone
4 anti-roll bar (two are hidden under body)





and 6 rear bushes in total
2 rear beam
4 anti-roll bar




Removal

There are only 4 tricky bushes; the two front wishbone bushes, and the two rear trailing arm ones. The rest are bolted in place by brackets , and can be removed with a socket set, with the exception of two of the outer rear anti-roll bar brackets (covered later*).

The general rule of thumb with bushes is sustained force (with a g-cramp or vice) is much better than a sharp shock (with a hammer or similar).

Here's how to remove the rear ones: -



Although it looks like the bush is damaged, it's just deforming as it passes through the bracket. They are surprisingly elastic…

The front wishbone bushes can be removed in a similar way, but it's hard to hold the wishbone and get some force on the bush with a g-cramp. In the end I gave up and used a hacksaw, but replacing them cost ?30. If you've got the time and patience I'd recommend persevering.

Refitting

Fronts

Here's how I refitted the front wishbone bushes - not very technical but it did the job!



The extension cable is there to guide the bush into the hole - you can use anything you have to hand. Use plenty of lubricant (supplied with the bushes) to ease assembly. Then just wind away…

It's not clear from the photo but one end of the bush is thicker than the other - force the thin end through the hole, leaving the thick end pointing towards the front of the car.


Rears

For the trailing arm bushes I used exactly the same tools and technique as for the front wishbones. The bushes are much bigger than the fronts though, and are a real faff to fit. If you swear at them enough and use enough force, they will go in.

The other tricky ones on the rear are the two outer trailing arm bushes, held in place by bands of steel and clips. Firstly screw the two inner bushes in place with the brackets, then press on the outer bushes onto the anti-roll bar. Then use a g-cramp to hold the band of steel in place, and a pair of mole grips to squeeze the top together: -



Then slide the clip over and gently tap into place with a hammer: -



Finally, remove the mole grips, hammer the clip all the way home, and tap the tab on the end to prevent it moving: -



*Removing the sliding clip can be very difficult if it's rusty - however if you're careful you can slice the clip with an angle grinder, and buy some replacements from VW. Be careful to leave the bands of steel undamaged, as they are are now obsolete…

Also, don't forget to put the stainless steel tubes inside the front wishbone and rear trailing arm bushes: -



HTH

Rich

Here's a few more photos of the fronts going together

1. Lightly grease the rear wishbone bush and slide it on to the wishbone



2. Loosely assemble the front wishbones and anti-roll bar



3. Tighten up the brackets that hold the wishbone and anti-roll bar in place



The wishbone brackets need 20Nm
The anti-roll bar brackets need 5Nm

4. Press the hoops over the anti-roll bar (you may need to squeeze them with a g-cramp before you can get the nuts on)



The anti-roll bar hoops need 25Nm

Finally, tighten the bolts through the front of the wishbone to 100Nm

HTH

Rich

this should be in the ''how to'' section

just received my new poly bushes and this comes in very handy