Unorthodox means of replacing rear diff bushings?

[tamadrumr88]

About a year ago I went to install the stern rear diff bushings. I was using a hydraulic press and the first bushing came out fine (a tad loud, but came out clean nonetheless) while the second (I believe it was the passenger side) put up a struggle. In the end the bushing did not budge and I ended up cracking the collar around the bushing (it's white aluminum so it's obviously not the strongest material known to man and I did not want to have it repaired because the heat from welding could possibly further weaken the material).

48 hours later I locate a spare rear diff crossmember at a cost of $60 and I attempt the same thing, ultimately cracking the passenger side collar of the rear diff mount while trying to remove that damned bushing. I curse myself, and my audi, and vow to never again attempt this procedure. I purchase yet another rear diff carrier and decide to stick with the stock rear bushings even though they clunk like a beast.... so I'm out $120, ~6hrs of my time, and nothing has changed.

Fast forward to today, I decide I want to again take on this behemoth. What are my options? Should I try first cutting the metal insert out first, remove the remains of the bushing, and try to press the metal sleeve out with a hammer/flathead screwdriver??? I've heard that pouring lighter fluid on the bushing and setting it ablaze may loosen things up a bit

Any other ideas? I really hope that the third attempt is successful

[Poopie]

hhmmm would take a torch and just burn them out.

[tamadrumr88]

How do you suggest removing the metal sleeve around the bushing inside of the collar??? If that doesn't come out the new bushings won't press into place

[1NaudiA4]

very careful with a saw zaw might work. I used a dremel with a hammer and chizel... worked wonderfully.

[Solaris]

I used a hacksaw to remove mine. Just be careful not to cut beyond that metal sleeve.

[audiness]

drill the shit out of them first. then chisel. then screwdriver.

[black00A4]

I used a heat gun, got them so hot they turned to plastic haha. Your best bet is heat but watch out cuz it stinks.