Even with an expensive blind hole puller set and map gas torch, it came down to just mangling it with a hammer and cold chisel set. This process sucked so bad. In hindsight I should've dropped it off at a machine shop, paid them their small fee, and saved nearly breaking a hand (due to some errant hammer strokes) and 4 hours of cursing. All done now, but that was the worst. Not an elegant process at all.

 

Morning follow-up. While pounding the new bushing in, somehow the pressure seized up the slip joint, now the driveshaft is stuck and the slip joint won't extend freely, thus, I can't re-install it since the flanges won't reach each other. In other words, the driveshaft is too short. I spent the last two hours trying everything to un-jam it and extend it. No luck.

New rear driveshaft and 4-flange conversion kit on the way. What a waste of a day.

 

I also destroyed my rear driveshaft in 2020 taking out that damn bushing / centering thing. Just bought a new one like you did. So you’re not alone.

 

Knowing this actually makes me feel less like a newb haha. Solidarity.

 

Is this part press fit or fit with heat normally, or does time just take its toll on the mating surface?

 

I honestly have no idea how it wears out. The spigot on the diff flange turns with it, so it’s not rotational friction. Maybe just overall rubber degradation?

 

What was the symptom that led you to the replacement effort?

Also, don’t feel bad. My in-line thermostat conversion ended up including a new radiator because I broke the stupid plastic nipple at the overflow. But it was probably good to have a new one anyway.

 

I had the drive shaft off to replace the transfer case output shaft bearing, so it was just a classic situation of an easy "while I'm in there" situation gone sideways. Overall it was pretty worn out, not much rubber left compared to the new one. It wasn't necessarily harming anything or creating an issue, but I was definitely expecting it to only be a one-beer job.

 

I had a stroke of genius last night on a long drive home. Worked like a charm - and took a ton of force - going to connect everything back up and hope it’s all good.

 

Reporting back, installed fine. The slip joint is super tight, but it's sort of always been that way.