pivot bar stuck

[micbrody]

hi,

after reading countless opinions of just getting new a-arms preloaded vs replacing bushings on old arms; I think I am stuck:

I removed the arms; I was able to press all four old bushings out. Pressed in my first lower arm bushing. Then went to insert lower pivot bar. I did not slide in easily. I figured I would just have to hammer it through. for the first few centimeters it advanced. But then it got harder to hammer. I sprayed some lubricant down and pivoted bar in the bushing, hoping it would lubricated. I hammered a little more. Now the pivot bolt not only doesn't advance anymore; it is now "married" to the metal inner sleeve of bushing.......... I think I am F-cked. Help!!!

[Nanonevol]

Using a metric hammer?

[micbrody]

Of course! and recently re-calibrated it

[micbrody]

for curiosity: I took old bushing and it when fairly snug but still easily on other side of pivot rod. I then took other new bushing (not mounted yet) and tried to put on rod. I could not....very snug......probably could use hammer. It got me thinking: Either the bushings are defective (too small) or the pivot rod is too big.
I had bought these bushings from Vicks about 13 months ago. I called them to see what their thoughts were. The guy I talked with was very helpful; he said they only had one other person call about this same issue. It turned out that the fiat pivot bolt was manufactured slightly too big. And the inexpensive solution is to purchase a new pivot rod (and one new lower bushing); or get a new pre-loaded a-arm.

Any thoughts on what he thinks is the problem? And I am leaning towards buying new arms.

[micbrody]

Some guarded success: I was able to back out pivot bar. I then took metal file and filed down the shaft where to bushing would rest. (Really took a very very tiny amount of metal reducing shaft diameter) . Tomorrow will again proceed with installing rest of bushings.

[RRoller123]

Can you post some pictures? That would help us help you.

[So Cal Mark]

"a few pivot bolts were manufactured too large", that's a new one. More than likely the bushings they sourced from India are out of tolerance

[micbrody]

I have been thinking about what the guy at Vick said. Most likely bushings are out of spec. If the factory had produced larger pivot bars than spec, they would have also had to make larger bushings to fit on them. Usually simplest explanation is the answer. As for my solution of filing the pivot arms: 1) I am dead in the water if I need either new bushings, pivot arms, or decide to purchase new pre-assembled a-arms. So in any of those scenarios, I have to waste time and spend cash. I decided to first see if I could make the busjings and rods work together. If I can get them to work, then the only worry I would have is when I need to replace bushings again, the "correct" busjings will be extremely slightly loose.......however by the time I need to change them, I most likely will be not driving (dead or nursing home); and in unlikely event I choose to rework suspension, there is no way in hell I would go this route( I would just buy new assembled a-arms)

[micbrody]

On a technical note: I have been thinking about the function of the bushing. Based on ability to "compress" rubber against inner sleeve by torquing the nut, I assume that it is desirable for a fairly snug fit of pivot rod on the inside metal sheath of bushing? Correct? That way, all movement (elastic compression) in bushing is between inner sleeve and the rubber (hopefully no movement between pivot rod and inner sleeve. Is that correct?

[JohnMc]

My two cents - get new bushings from AR and see what the deal is. I surmise the current bushings you have were made out of spec.

[kmoses]

+1 for getting new bushings from AR. I ordered bushing from one vendor (not Vick's) and the OD was .025" smaller than the ones I press out. Contacted AR about theirs and one of the guys actually measured it with dial calipers to confirm the size, and they worked perfect when I received them. I will say that in my short time as a Fiat spider owner (7 months) I have purchased a lot of new parts that had to be machined in one way or another just to be used or reordered from another vendor.