Mutt Motorpool
Installing Front End Poly Bushings
on the M151
on the M151
This instruction sheet assumes the control arms have been removed from the vehicle.
1. Thoroughly clean or bead blast the control arm assemblies.
2. Mark the side of the shaft and the control arm that has two (2) washers on it with a punch or some other
method.
3. Remove the cotter pins, nut and washer on the side with the single washer.
4. With an exacto knife cut off the rubber on the inside (towards the center) of the old bushing (see photo)
1. Thoroughly clean or bead blast the control arm assemblies.
2. Mark the side of the shaft and the control arm that has two (2) washers on it with a punch or some other
method.
3. Remove the cotter pins, nut and washer on the side with the single washer.
4. With an exacto knife cut off the rubber on the inside (towards the center) of the old bushing (see photo)
5. Grind the side of the shaft that has the single washer on it around the mounting bolt area to allow the shaft
to fit in the outer sleeve after removal of the rubber bushing. (See photo).
to fit in the outer sleeve after removal of the rubber bushing. (See photo).
6. To remove the rubber bushing from the outer steel bushing on this side, first loosen the nut on the side that
has two washers on it. (Loosen the nut so that it is still barely on the threads). While rotating the shaft, push the
shaft and the inner sleeve out of the rubber bushing. You may have to apply a small amount of oil to the inner
sleeve if it doesn't slide out easily and grab it with the pliers and pull, while pushing the shaft. If it doesn't want to
move and feels stuck to the rubber, put the nut back on and tighten it so that you can turn the shaft and the sleeve
turns at the same time breaking the bond between the inner sleeve and the rubber. Lightly oil the inner sleeve and
start again. With the inner steel sleeve removed it's very easy to remove the rubber from the outer sleeve, either
by cutting it out or by pulling with the pliers.
7. Since the outer sleeve has to been pressed into the control arm, the smaller end needs to be filed around
the inner lip. This is done to make inserting the polyurethane bushing much easier.
8. Remove the nut and washer from the side that has two washers. Slide the shaft through the outer sleeve of
the side with only one washer and remove it completely.
9. Remove the excess rubber from the inside of the remaining bushing (the side that had two washers on it)
Remove the inner sleeve from the rubber. If you experience trouble you can remove the shaft and put the large
holed washer on backwards and reinstall the shaft and tighten the nut down and turn the shaft just like the other
side and push the inner sleeve out until you reach the washer. Remove the nut and washer and pull the inner
sleeve out of the rubber bushing. You may have to apply a small amount of oil to the inner sleeve if it doesn't slide
out easily and grab it with the pliers and pull. With the inner steel sleeve removed it's very easy to remove the
rubber from the outer sleeve, either by cutting it out or by pulling with the pliers.
10. Again since the outer sleeve had to be pressed into the control arm, the smaller end needs to be filed
around the inner lip. This is done to make inserting the polyurethane bushing much easier.
11. With a round wire brush clean the inner surface of all of the outer bushing. I used a drill with a round
wire brush, but any wire brush will work, just as long as the inner surface is clean.
12. Clean the threads of the shaft and the surface area that the inner bushing rests on.
13. Lubricate the inside surface of the outer sleeve (the part still in the control arm) of all of the outer metal
sleeves still in the same arm with the lubricant supplied with the polyurethane bushings. Insert a polyurethane
bushing (1 of 4) from the kit 3.5118G in the inside of the outer sleeve. Next insert another polyurethane bushing
(2 of 4) from the outside of the outer sleeve. NOTE; This is done only on the side that has two washers. When
you are finished with one end of the control arm the new polyurethane bushings will be installed from each side of
the outer sleeve only on the end that had two washers on it.
14. Lubricate the inside of the new polyurethane bushing and the outside of the new inner sleeve. Press the
new inner sleeve, with the newly chamfered end first, into the polyurethane bushings. It doesn't matter which way
you press the inner sleeve in as long as you keep the polyurethane bushings from being expelled from the control
arm. I put the inner sleeve in using a vice clamping on both sides at the same time. The same can be done using a
"C" clamp. NOTE: Do not use the sleeve that came with the Kit #3.3123G, that you cut-to-length, for the end
with the double washers on it, it's to long.
15. Install the shaft into the control arm assembly with the larger holed washer in the same position (inboard)
as you took it apart. Lubricate the inside of both of the washers to prevent premature wear of the bushing. Install
the nut and washer on the outside, do not tighten the nut at this time.
16. On the remaining side (the one with only one washer) you will install a polyurethane bushing
(cut-to-length) that came with kit # 3.3123G. Lubricate the outer surface and inner surface of the polyurethane
bushing ( cut-to-length) and work it into the outer sleeve.
17. Now it's time to install the remaining inner sleeve into the single long polyurethane bushing that you just
installed. By starting the newly chamfered end first and loosening the nut on the double washer side you may be
able to get the nut and washer (on backwards) to start. Tighten the nut until it gets hard, but do not force it. Them
remove the nut and put the washer on correctly. Torque to the correct spec.'s install new cotter pins and your
ready to install the arm just completed. The procedure is the same for all control arms of the Mutt.
If you have any questions, or response to this modification, you can e-mail me at dyansty@ilhawaii,net . I hope I
didn't forget or leave anything out regarding the polyurethane bushing modification.
We hope you will be pleased with your Mutts new suspension feel.
Mahalo,
Ron Rietfors
has two washers on it. (Loosen the nut so that it is still barely on the threads). While rotating the shaft, push the
shaft and the inner sleeve out of the rubber bushing. You may have to apply a small amount of oil to the inner
sleeve if it doesn't slide out easily and grab it with the pliers and pull, while pushing the shaft. If it doesn't want to
move and feels stuck to the rubber, put the nut back on and tighten it so that you can turn the shaft and the sleeve
turns at the same time breaking the bond between the inner sleeve and the rubber. Lightly oil the inner sleeve and
start again. With the inner steel sleeve removed it's very easy to remove the rubber from the outer sleeve, either
by cutting it out or by pulling with the pliers.
7. Since the outer sleeve has to been pressed into the control arm, the smaller end needs to be filed around
the inner lip. This is done to make inserting the polyurethane bushing much easier.
8. Remove the nut and washer from the side that has two washers. Slide the shaft through the outer sleeve of
the side with only one washer and remove it completely.
9. Remove the excess rubber from the inside of the remaining bushing (the side that had two washers on it)
Remove the inner sleeve from the rubber. If you experience trouble you can remove the shaft and put the large
holed washer on backwards and reinstall the shaft and tighten the nut down and turn the shaft just like the other
side and push the inner sleeve out until you reach the washer. Remove the nut and washer and pull the inner
sleeve out of the rubber bushing. You may have to apply a small amount of oil to the inner sleeve if it doesn't slide
out easily and grab it with the pliers and pull. With the inner steel sleeve removed it's very easy to remove the
rubber from the outer sleeve, either by cutting it out or by pulling with the pliers.
10. Again since the outer sleeve had to be pressed into the control arm, the smaller end needs to be filed
around the inner lip. This is done to make inserting the polyurethane bushing much easier.
11. With a round wire brush clean the inner surface of all of the outer bushing. I used a drill with a round
wire brush, but any wire brush will work, just as long as the inner surface is clean.
12. Clean the threads of the shaft and the surface area that the inner bushing rests on.
13. Lubricate the inside surface of the outer sleeve (the part still in the control arm) of all of the outer metal
sleeves still in the same arm with the lubricant supplied with the polyurethane bushings. Insert a polyurethane
bushing (1 of 4) from the kit 3.5118G in the inside of the outer sleeve. Next insert another polyurethane bushing
(2 of 4) from the outside of the outer sleeve. NOTE; This is done only on the side that has two washers. When
you are finished with one end of the control arm the new polyurethane bushings will be installed from each side of
the outer sleeve only on the end that had two washers on it.
14. Lubricate the inside of the new polyurethane bushing and the outside of the new inner sleeve. Press the
new inner sleeve, with the newly chamfered end first, into the polyurethane bushings. It doesn't matter which way
you press the inner sleeve in as long as you keep the polyurethane bushings from being expelled from the control
arm. I put the inner sleeve in using a vice clamping on both sides at the same time. The same can be done using a
"C" clamp. NOTE: Do not use the sleeve that came with the Kit #3.3123G, that you cut-to-length, for the end
with the double washers on it, it's to long.
15. Install the shaft into the control arm assembly with the larger holed washer in the same position (inboard)
as you took it apart. Lubricate the inside of both of the washers to prevent premature wear of the bushing. Install
the nut and washer on the outside, do not tighten the nut at this time.
16. On the remaining side (the one with only one washer) you will install a polyurethane bushing
(cut-to-length) that came with kit # 3.3123G. Lubricate the outer surface and inner surface of the polyurethane
bushing ( cut-to-length) and work it into the outer sleeve.
17. Now it's time to install the remaining inner sleeve into the single long polyurethane bushing that you just
installed. By starting the newly chamfered end first and loosening the nut on the double washer side you may be
able to get the nut and washer (on backwards) to start. Tighten the nut until it gets hard, but do not force it. Them
remove the nut and put the washer on correctly. Torque to the correct spec.'s install new cotter pins and your
ready to install the arm just completed. The procedure is the same for all control arms of the Mutt.
If you have any questions, or response to this modification, you can e-mail me at dyansty@ilhawaii,net . I hope I
didn't forget or leave anything out regarding the polyurethane bushing modification.
We hope you will be pleased with your Mutts new suspension feel.
Mahalo,
Ron Rietfors
