Dana 18 rebuild, help please.

A press is the best way to go, but if you are going to resort to a hammer, then it is best to use a piloted driver for the bushing.

If you can get access to a lathe, make up a driver, you want the driver to have a piece that fits into the bushing, and then steps up in diameter to just under the outer diameter of the bushing.

It will look a lot like a clutch alignment tool, minus the splines. Flat face on the part that actually drives the bushing.

This will allow you to keep the bushing straight as you drive it into the hole. The pilot stub inside the bushing is the key here.

 

Gotcha kind of like the output clutch shaft itself. I will press it in.

An old output clutch shaft would be a good item to use for installing those either way.

 

I read that you have to bore the bushing after it's in to match the shaft size ie. it comes from the factory too small. Is that correct?

 

NO, some of them have to be hand reamed but most do not.

 

This is my experience today and now searching for some reemers.

 

Measure.

 

https://www.mcmaster.com/reamers/high-speed-steel-round-shank-reamers-10/

 

Maybe in the old days--- I've had to ream every one of late. As Tim said: measure. If you don't have a caliper or micrometer, buy one! For this exercise, the HF versions would suffice.

 

This is a good source for me. Thanks!