inner lower control arm bushing

[Junkman]

I'm redoing the suspension on the 85SD and have run into a little issue with the lower inner control arm bushing. I made a press of threaded rod and washers and thought all was well - UNTIL one cap on the control arm wouldn't press all of the way in. Both caps are bottomed on the metal of the center bushing. I'm using a Lemforder bushing which is the correct PN 126-30-00-75

Bushing link here. 1984 Mercedes-Benz 300SD Base Sedan - Suspension, Shocks & Springs - Page 2

Another thread showing the install here: Write up - Ball Joints & Lower Control Arm Bushings & Tool Review (PICS!)

See the last pic in post 9 for what it is supposed to look like. Mine is standing off about 1/4".

Any ideas other than starting over? A friend at a machine shop didn't have an easy way to support the end without interfering with the part that needs to move.

I'm wondering whether putting the center piece in first would work better. Then I could use the threaded rod and washers on both caps at the same time. I have an extra bushing in hand if needed but don't want to mess that one up.

Edit: I'm going to begin again. Does anyone know the factory tool for installing? I've read plenty of threads and none have run into this issue. I thought I was on the downhill slide with how easily the bushing and 1st cap went together. I'm open to suggestions.

[Diesel911]

I think even the Chinese copies of the real bushing tool are not cheap. You see the copies on ebay ane Pelican should have the real Tool.

The attached .pdf is for a W123 but first shows the typical W123 Bushing and then page down and it has the 3 piece W126 type Bushing.

It shows the Tools and more impartanly there is a cut away drawing showing what the Tool preses own when you are installing the Bushings.

On mine the Bushings also wanted to creep out a little. I squeesed them in with a vice and left them over night compressed like that and they next moring the stayed in place. Then I installed the Aluminum Tube (my bushings were different then yours).

[SD Blue]

As you mentioned, I found it worked easiest to put the center portion in first. Use a water-soluble lube (such as KY) because the flats of the inner portion of the bushing need to line up with the flat of the control arm.

I then used all-thread, nuts and washers, and appropriate 3/4" drive sockets in order to press the caps onto the center portion of the bushing, one at a time. This is the same method shown in the FSM and using the factory tool. http://www.startekinfo.com/StarTek/outside/12253/program/Chassis/33-520.pdf

From your description, it sounds like one of the caps became deformed. This is usually due to pressing on the end of the cap, rather than the outer lip as shown by the red ring in post#10 of your installation reference link. (This is where the 3/4" sockets come into play.)