Last night I had my first opportunity to use the Volvo Bushing Tool I picked up on ebay a few years ago. To my surprise, the "sleeve" into which the old bushing is to be pulled is too small to fit around the end of the bushing. The new bushing slides easily through the sleeve. As far as I know, there is only one size for the large bushing. The tool is the actual Volvo tool and the part number on the tool matches the factory manual which I am also using. Should be an easy job but??? Which direction should the taper on the bushing be pointed (in or out)? It seems to be pointing out on the one in the car (original or old replacement). Opinions? Thanks.

Skip
'93 850GLT
'89 765T
'83 242TI Flathood

I just did the job on my 1990 240 yesterday and today. Plan more time than you think. The bushing on the left would not budge. I tried PB blaster. I actually broke the #8 bolt. (fortuately I bought 2) Finally came out after cutting much of it with a small grinder. Had to remove the inside steel tube with the tool and finish it with a 14 inch pipe wrench.

The second one I used the grinder before I started. Used the grinder to cut a channel just through the metal of the bushing on the lower edge. Used a chisel to break any metal remaining in the channel. Used the chisel to whack the bushing where it contacted the dog ears. Lots of PB Blaster before and after the chiseling (it you don't have a grinder I bet a drill will accomplish the same thing.) The second one came right off.

Freeze the new one for a couuple of hours before your install, and clean out the rust from the dog ears. The new one will slide right in.

It's a lot of work but worth it.

Hard to picture but from what I can tell. Because the Rubber and metal tube that passes thru on the old bushing is prbably mangled, the Bushing Puller is offset a bit causing the old bushing to bang into the 'receiver'. Can you make the Bolt tight on the Tool then tap the bolt close to center (on the old bushing) then try pulling it out?
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'75 Jeep CJ5 345Hp ChevyPwr and two motorcycles: it wasn't Volvos safety , it was Longevity that sold me

Duane Hoberg has some good photos of the Volvo tool and its application.
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Art Benstein near Baltimore