Wall of text!
Sub-frame and bushing replacement story.
I recently purchased this 2011 nissan versa (101k miles) from a repo auction $2,500. After getting the car for the auction, the first thing I did was to change the oil and get new tires to get the car on the road.
Unfortunately, I failed my inspection because of a sub-frame bushing. I did some research and decided to try and tackle it myself.
At first I tried to partially drop the sub frame and get the bushing out, NO LUCK, thanks to NY salt. So after doing a little more research, dropping the entire sub frame seemed easy enough….. argh!
During the sub-frame bushing replacement, I encountered 3 major problems and 1 minor one.
1st Major problem, the lower ball joints
It was next to impossible to separate from the knuckle. Again, thanks to NY salt. I tried Large hammers and mallets, I even tried to jack up the knuckle while having a ratching tie-down strapped around the lower control arm and the base of the jack. No luck.
I eventually got 2 pickle forks and had to hammer both in from opposite direction to separate the joint. Of course, the pickle forks destroyed the ball joint. It’s at this point I decide to order two new Moog lower control arms.
During re-assembly, The Moog control arms bolted into the sub frame and knuckle without issues. I did load up the post on the ball joint with lots of anti-seize before I re-installed them.
2nd Major problem, removing bushings
After removing the sub-frame out of the car, I encountered the next Major issue. It was removing the old bushings. Here in NY they were fused to the sub-frame. I highly recommend lots of Heat (map gas)+ 1-1/8 socket and a large hammer. This combination very successful.
3rd Major Issue, Putting the bushings back in
The 3 Major issue, was trying to get the new bushing back in….. complete failure. I used a very large bolt and lots of washer to try and pull the bushing into the sub-frame. At one point, I heard a very large pop that came from the sub-frame, like a weld had broken. I inspected a bit, but did not see any damage. Then a few minutes after that the pulling bolt I was using snapped in half with the first bushing only about 70% seated……..
I’m not proud of it, but the stress of getting this car back operational during the weekend started to impact me. I made the decision to just purchase a new sub-frame, and even worse, from the dealer. $$$$+first born
Luckily a local dealer had the part and I could put the car back together that day.
The 1 minor issue is with my steering wheel. It now sits off about 25 degrees. I took what I thought were the correct steps to prevent this. I kept my steering wheel from moving, and used a paint marker to mark the lower steering joint and steering gear orientations. However, my steering wheel is still off by 25 degrees when the wheels are straight.
I’ll have to inspect further to see what’s going on. I’ll also will need an alignment very soon.
Lessons learned and things I might try differently.
1) Sanding out the sub-frame bushing hole a little better to cut down on the friction while inserting the bushing.
2) Unbolting the control arms from the sub-frame and leave them on the knuckle.
3) Having the new bushings professionally press into the sub-frame.