my pilot bushing is officially stuck. I tried the toilet paper and socket method. My pilot bushing is so worn that the 13mm socket was loose, but 14 mm was too big. The standard sizes had similar problems. I then "fabricated" a piece of metal rod. I essesntially took some pipe I have laying around that fit perfectly and welded the end shut. Some how toilet paper was able to come out. I then tried a chisel to break it apart. I figured good sharp ones were necassary so I used my good work chisels. I now need two new chisels.

there is definitely not enough room back there for a slide hammer claw. My bushing is so worn there was a bunch of round metal shavings that looked like a lathe turned it, and some of it pack itself in the back. My toilet paper adventure definitely did not help. Any others ideas? I guess I could figure out what size tap I would need, but I am sure that a tap in its size would not be cheap. I read of one guy using a 1" hole saw but I am kind of wary of that, seems pretty unsafe and I am afraid to scuff the inside of the crank. any one have any ideas or methods that worked?

 

Try packing grease in the hole and then find a bolt the same size as the hole. Tap the bolt in and the grease should push the bushing out.

 

I am now very confident that a 1" hole saw is not very wise. My anticipated outcome came true and I beleive I am have slightly nicked the crank so I stopped. a 7/8" hole saw would have been a much better idea. The opening diameter of my worn out bushing speced out to be .76". Tomorrow I am going to go to the hardware store and grab a 3/4" bolt and drive it in with my impact. I think that should either pull it out, or at least give me some surface area to weld crap to so I can knock it out with a sledge hammer.

 

my micrometer is definitely pretty accurate. tried a 3/4" tap and a 3/4" bolt today with no luck. They were too loose. Next I decided to rent a pilot bearing puller. No luck. Next I used a 7/8" hole saw through it. Its pretty destroyed but still stuck. I just turned the compressor on and am going to attack with an air hammer next.

 

air hammer for a couple minutes and it was game over. Can anyone confirm if there is supposed to be a small lip in the back of the crank where the pilot bushing is inserted?

 

Yep, just by "eyeballing" an extra LT1 crank I have sitting in my garage .... there IS a little lip about 1 inch down the hole where the pilot bearing goes. Hope this helps.