Just how tight are new spring bushings supposed to be?

[GeologistFelix]

So, long story short, I'm doing a budget minded OME spring lift, keeping all the factory hardware, since my rig has next to no rust down there beyond a surface patina under the grime and grease. I got the original springs, u-bolts, shackles, and fixed-end spring pins loose with only a day of penetrating oil soaking on the key hardware. Not a single stripped thread.

Anyway, here's the problem: my new Energy Suspension poly bushings are insanely tight on the factory shackle and spring pins. They're for an FJ60 according to the packaging, and fit in the spring eyes perfectly, but the pins just don't want to go in. I used the pre-lube (ew) supplied with the bushings, and it barely helped. I also took off the thin layer of rust mixed with ancient rubber on the pins and sanded them down to smooth bare metal, and that also barely helped.

So, what gives? Am I just not trying hard enough? Is this a common leaf spring problem?

 

[SteveH]

I have used Energy Suspension bushings on my '60 and '62 (most recently) and they fit pretty well. I made sure the shackle bolts/rods were shiny clean, and used their lube (and some other when I ran out). Once you get it back together, the vehicle weight will surely egg out the holes. In some cases, I have had to pound off the not-so-thin layer of rusty chunks on the pin, to reduce its diameter to that of the underlying metal. (The rust had 'swollen' the pin, if you will). If you can physically put it together with some pounding, I wouldn't sweat it. I presume you're SURE you got the correct kit for an FJ60?

Since your other choices are OEM rubber and 'eBay who knows what' - what brand of bushings does anyone else, besides Energy Suspension?

 

[GeologistFelix]

Double checked my order, the packaging, etc., and confirmed I got the right bushings, 100% certain.

That made me wonder just how far from spec the bushings are, so I took a look at everything with digital calipers.

Long story short, the bushings were 17.8 mm inside, and my still somewhat rusty Toyota spring eye and shackle pins were around 18.2 mm, and definitely a lot rougher than new, shiny pins would be.

So, I put sandpaper on a dowel to make a little hillbilly spindle sander out of my drill press and carefully took all the pins down to clean, bare metal.

As of a couple of minutes ago, I have the front end all back together and just have to go through all of this again with the rear axle.

 

[Godwin]

I used the Energy Suspension bushings 8.2106G to replace OME bushings and had no trouble with the installation.