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Carli trackbar bushing replacement.......

Postby TwinStick » Wed May 17, 2017 7:30 pm

So, after replacing the shifter boot today on the G56, I figured I'd try to tackle the Carli trackbar bushing replacement (not the heim joint). Started out well, bolt came off easier than I thought. But the bushings & the sleeve.... :shock: What a royal PITA. After an hour or so of trying to get old stuff out, they finally came out. Broke 2 C-clamps in the process. The inner metal sleeve was corroded beyond all get out. I suspect that was part of the problem of why the bushing were not coming out, because it was bigger than stock because of the corrosion.I had to use the belt sander on it. CARLI SHOULD INCLUDE A NEW METAL SLEEVE WITH THE REPLACEMENT BUSHING. Also had a hell of a time getting new ones in, even though everything was lubed. Wife was needed for a second set of hands for the install of the new stuff. Got done & cleaned up just as it got dark. Used both feet against the tire, a 1/2" breaker bar with a pipe extension & gave it all I had for torque, after using my 18v elec impact wrench. Ended up taking longer than the shifter boot.
Last edited by TwinStick on Thu May 18, 2017 6:52 am, edited 1 time in total.
2008 Red QC PW G56. No lift yet, stock size tires. It pulls a 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????
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Re: Carli swaybar bushing replacement.......

Postby ramv » Wed May 17, 2017 9:39 pm

After having my wife help install a new T-case in my Chevy 2500 I don't think she would help with sway bar bushings. Good work!
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Re: Carli swaybar bushing replacement.......

Postby Colibri » Wed May 17, 2017 10:44 pm

Are you talking about the trackbar bushing?
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Re: Carli trackbar bushing replacement.......

Postby TwinStick » Thu May 18, 2017 6:53 am

Yes, trackbar bushing, sorry. It was a long day. I'll fix that.
2008 Red QC PW G56. No lift yet, stock size tires. It pulls a 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????
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Re: Carli trackbar bushing replacement.......

Postby Colibri » Thu May 18, 2017 1:05 pm

Man that sounds like a rough time you had, unfortunately without a bench vise I don't know of an easier way to tackle that job. Kudos to you for getting it done sir :rockon:
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Re: Carli trackbar bushing replacement.......

Postby coder » Thu May 18, 2017 2:24 pm

TwinStick wrote:So, after replacing the shifter boot today on the G56, I figured I'd try to tackle the Carli trackbar bushing replacement (not the heim joint). Started out well, bolt came off easier than I thought. But the bushings & the sleeve.... :shock: What a royal PITA. After an hour or so of trying to get old stuff out, they finally came out. Broke 2 C-clamps in the process. The inner metal sleeve was corroded beyond all get out. I suspect that was part of the problem of why the bushing were not coming out, because it was bigger than stock because of the corrosion.I had to use the belt sander on it. CARLI SHOULD INCLUDE A NEW METAL SLEEVE WITH THE REPLACEMENT BUSHING. Also had a hell of a time getting new ones in, even though everything was lubed. Wife was needed for a second set of hands for the install of the new stuff. Got done & cleaned up just as it got dark. Used both feet against the tire, a 1/2" breaker bar with a pipe extension & gave it all I had for torque, after using my 18v elec impact wrench. Ended up taking longer than the shifter boot.
Are you talking about the poly bushings on the drivers side frame?
Vehicle: 2007 Power Wagon Quad Cab - Inferno Red
Suspension: Carli 3" Hemi Coils, Carli Control Arms, Carli King 2.5 Pin-Tops, Carli Stainless Steering Stabilizer, Carli Trackbar | Synergy 1" Rear Shackle
Performance: Magnaflow Muffler | Magnaflow Y-Pipe
Wheels/Tires: Toyo AT II's 35x12.5x17
Steering/Drivetrain/Axles: Carli Front Diff Guard | Dynatrac Ball Joints | Redhead Steering Gear
Miscellaneous: Line-X Bedliner | Locker Bypass Switch | Mopar Rock Rails | DieHard Platinum Battery G65 | Performance Friction Brake Pads | Weathertech Digital Fit Mats | Winch Thermal Protection Bypass
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Re: Carli trackbar bushing replacement.......

Postby TwinStick » Thu May 18, 2017 4:36 pm

Yes.

I could hear my neighbor doing dinner dishes from her kitchen window, while I was working on the trackbar. Conversation went kinda like this: ME: - Why you dirty rotten SOB, Mother F***er, Ahhhhh, @$%*&^!#@ !!! Neighbor lady: working on the cars again Mike ? :oops: :oops: :oops: Ahhh, yup, sorry.


:lol:
2008 Red QC PW G56. No lift yet, stock size tires. It pulls a 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????
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Re: Carli trackbar bushing replacement.......

Postby DamageWagon » Thu May 18, 2017 9:29 pm

That sucks man, I've never had corrosion issues with mine but I have Rusty's old bar and the heim was a rust bucket. I can pull my bar, replace the heim and bushings, adjust and reinstall in under 60 minutes now (not a mark of pride, I just let having Trackbar problems).

The bushings are designed to be a press fit, generally requiring a vise for install. The problem with mine was that it slipped right in, no press fit, which was "unheard of and extremely unlikely" per the two individuals that have a public voice at Carli. Did you use a vise to install the bushings? Carlis are difficult in that they flare out where they are to be pressed in.
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Re: Carli trackbar bushing replacement.......

Postby TwinStick » Fri May 19, 2017 12:45 pm

No vise. Did it while it was on the truck. Used Big 8" C-clamps (made in China is all I had). Broke 2 of them. Finally, I found a scrap piece of thick aluminum and a scrap piece of steel. Put one over the open side of track bar & the other over the bushing half. With the wife helping, that did the trick. Got one side in, then the other. The metal sleeve almost broke my last 8" C-clamp, trying to get it in. I have a new heim as well but it still seems tight. Next time, I will replace both at the same time & remove it to do it.
2008 Red QC PW G56. No lift yet, stock size tires. It pulls a 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????
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Re: Carli trackbar bushing replacement.......

Postby RustyPW » Mon May 22, 2017 9:23 pm

DamageWagon wrote:That sucks man, I've never had corrosion issues with mine but I have Rusty's old bar and the heim was a rust bucket. I can pull my bar, replace the heim and bushings, adjust and reinstall in under 60 minutes now (not a mark of pride, I just let having Trackbar problems).

The bushings are designed to be a press fit, generally requiring a vise for install. The problem with mine was that it slipped right in, no press fit, which was "unheard of and extremely unlikely" per the two individuals that have a public voice at Carli. Did you use a vise to install the bushings? Carlis are difficult in that they flare out where they are to be pressed in.

What's funny. Brand new, I never had to use a vise to press the bushings in on that bar.
PWOC #53
2008 POWER WAGON RC
Mods to the PW; Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper , PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN'.

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Re: Carli trackbar bushing replacement.......

Postby DamageWagon » Mon May 22, 2017 9:49 pm

My Carli bushing slipped right in and only lasted 3000 miles before ovaling. My Thuren bushing I had to press on with the vise, very tight, then fight with a hammer and both my legs pushing it in just to install in the truck. Squeaking just started under the front end with any suspension movement and I'm wondering if it's the bushing, if so I'm happy!
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