Need Someone With Machinist Knowledge Too Look At This Thread

[Diesel911]

If you read this thread you can get some idea what People are doing. I go by 300Dman on this Forum.

VWDieselParts.com • View topic - injection pump shaft bushings

[Dan Stokes]

I'd be very nervous about pressing bushings into a bore then pressing them out and back into another bore. Every time you press the bushing in it looses some of it's od and therefore does not crush to the same size it was in the bore you used to size it. Furthermore, you've lost some of the crushed fit which means that the bushing isn't held as firmly in the final bore as it's supposed to be. Press fits and crush fits (look those up in a Machinery's Manual - there are specific definitions) are critical and can be lost if not done properly.

That said, you might be able to freeze the bushing when installing it in the final bore and get it in with little dimension change - but that assumes that the bore in both the pump casting and the reaming jig that you've made and identical - not likely. If those bores aren't identical the bushing won't end up reamed to it's ideal size anyhow.

The concept of sizing the reamer makes a ton of sense. It sounds like your reamer is a tad oversized and if you're careful you can fix that. Then you can press the bushing in and properly size it in it's final location. It may take a few bushings to zero in on the correct reamer fix.

Dan

[Diesel911]

Originally Posted by Dan Stokes

I'd be very nervous about pressing bushings into a bore then pressing them out and back into another bore. Every time you press the bushing in it looses some of it's od and therefore does not crush to the same size it was in the bore you used to size it. Furthermore, you've lost some of the crushed fit which means that the bushing isn't held as firmly in the final bore as it's supposed to be. Press fits and crush fits (look those up in a Machinery's Manual - there are specific definitions) are critical and can be lost if not done properly.

That said, you might be able to freeze the bushing when installing it in the final bore and get it in with little dimension change - but that assumes that the bore in both the pump casting and the reaming jig that you've made and identical - not likely. If those bores aren't identical the bushing won't end up reamed to it's ideal size anyhow.

The concept of sizing the reamer makes a ton of sense. It sounds like your reamer is a tad oversized and if you're careful you can fix that. Then you can press the bushing in and properly size it in it's final location. It may take a few bushings to zero in on the correct reamer fix.

Dan

If I cannot stone the Reamer down I guess I can fall back on the Expansion Reamer.
To Stone them by Hand is easy to get all 8 of the Blades the same size is not.

I have not taken any pics of the Bushings but they are Steel Backed. If they are pressed into an Aluminum Housing the I think the Housing would be what wears.

The other forums recommend using Red Loctite During Installation. That is easy enough to do.
The Guy on the other Forum said he got the .001" clearence spec from Bosch Repair Shop.

This makes Me think that the Tech is speaking of what the Bushings are like when they replace a whole new Housing.

Sorry I am not making better progress on this issue.
I am having to get a Car that was given to Me that sat 5 Years ready for the Smog Test and I spent from 7:30AM-2:00PM down at the VA Hospital Today.

I did have time to look in My Tools and I have a 21/32 Drill Bit with a good edge on it. So that will be a big help getting the ID of the Reamer Guide close enough so the Reamer does not have to cut so much out.

I am waiting for the Shipping cost on some less expensive Bushings and some other items in case the Bushing Reaming ends up Too oversized.