Freise

This is on a 95 KA24DE + Tranny, stock manual (not swapped from auto).

When I replaced my pilot bushing, I pulled the old one out using a slide hammer. I had a new one, ordered from online, that I attempted to get in by hitting it with the slide hammer, and it ended up cracking and exploding. So I went to autozone and bought a second one. This time I actually noticed that the diameter seems a little too big for the hole, so I tried to be more careful this time. I failed, ending up in the exact same situation as the first. So I went back to a different autozone, got a 3rd one, and guessed that maybe the diameter is just a little too big again, so I polished it down a bit. Hammered it in lightly with a socket, and got an extremely tight fit after about 30 minutes of tapping.

Well, the fit is soo tight that I believe the bushing may be compressed slightly, since the input shaft does not fit in at all. The alignment tool does not fit in unless I grind it down first. I've tried grease and everything. I have a 4th new pilot bushing that I got with an ACT clutch kit, and eyeing up the original old bushing versus the new ACT one, it seems that once again, the outter diameter of the new one is just slightly bigger than the original old bushing.

Does anyone have advice on what to do? I guess I don't understand why none of the pilot bushings fit. The way I see it, I can either grind down both the outter AND inner diameters of the new pilot bushing, hoping that it won't reduce it's integrity very much, or I suppose reinstall the original old one, it is seems to be in a decent condition, no cracks or too much wear, but I hate to leave a potentially 15 year old item alone if I'm down there replacing stuff anyways... Or, should I give the $20 Nismo Pilot bushing a try? It supposedly has bearings to prevent it from ever "wearing" and hopefully make it easier to install, but I've ordered from an online store, from autozone, and from ACT, the bushing that is suppose to fit, so I'm afraid the Nismo one won't either.
Thanks
-Tim

S14DB

Nismo Pilot bushing.

Had the same problems with pilot bushings as you on a friends car. I got the nismo when I swapped my clutch and had no problems.

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Comments should be taken as Opinions not as Statements of Fact

Freise

I tried sanding the inside of the bushing with a dremel, the alignment tool fits now so I believe the input shaft will, however I just went and broke a flywheel bolt lol I'll update if this works

heavenboundkevin

i think i had a oem one, and it went in fine, i used a socket to tap it in. i did have to shave the alignment tool, i figure the alignment tool was at fault for not fitting, not the bushings fault.

so youre only haveing problems with the bushing right? not the "input" shaft?

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Killa_D

i put my on the freezer for about 3 hours and tap it in with a socket works like a charm every time.

Freise

The alignment tool I used (and had to shave down) had been used on other KA's with a perfect fitment, so I had the benefit of knowing it wasn't the alignment tool. They dremel sanding bit worked like a charm, I blew out all the shavings with compressed air, greased her up, and got the tranny in with only about 20 minutes of fuss. Ironically the sanding bit for the dremel is almost the exact diameter of the inside of the pilot bushing, I just sanded the inside about 3 passes, very little material removed, but input shaft slid in nice and snug.