Guys, been working on the Defender to swap out the crazy height suspension on the TD5 today, read an LRO article where they did it and the mechanic said 25 mins tops on each corner to remove and replace the spring and shocks. Seemed reasonable, its just bolts.

First one took just over an hour, and so I was happy with that.

Second rear corner I've so far spent 4 hrs on it. For some reason the top shock mount is too big for all the bushes, any bushes, even the old bushes wont go back on. I managed to get the first bush on (poly), then mount the shock but the 2nd bush just will not fit, there's something odd about the shock mount.

I've tried heating the bush in boiling water, using WD40, grease, nothing has worked and I'm not at the end of my patience

The only thing I can think of to try is to go at the mount with an angle grinder and sanding disc and trying to take it down slightly.

Would it be stupid to cut a slit in the bush in order to make the internal diameter larger? Would it matter really if there was a slice in it? I can't see how it would perform any less?

Anyone got any advice before I get REALLY angry? Discovery 4 HSE
1998 110 TUM HS FFR Hard Top XD WOLF
1982 Series 3 Hard Top

*Gone:L462 D5 HSE LUX, L663 Defender 110 HSE, Discovery 3 HSE, 2014MY Range Rover Sport 5.0 Supercharged AB Dynamic; L405 Exec Vogue SE 4.4, 5.0 Supercharged Autobiography, Defender TDCi XS CSW, Defender TD5 HT, Vogue SE TDV8, Vogue TD6, RRSport SC 4.2V8, Classic 3.9 Vogue Auto, Land Rover Series 3 SWB

To me, I'd consider replacing the shock mount. I assume, possibly, that the shock mounts may have been changed with the lifted suspension?

Tolerances may be doing this. A new part (genuine and not that expensive) should be better. Easy job.

Or maybe freeze the mount and heat the bush.

Out of interest, how easy was it to remove the shock? Is the mount slightly rounded (collared) on the outer circumference? Might just need a good rough wet n' dry? Si. <This is my name.

I eat rat poison.

A man ain't truly been insulted until he stands buck naked in front of a woman and she didn't even notice. Or care.

I have already wet and dried with wd40 but no luck, though lovely and smooth!

Tomorrow I will try boiling the poly bush in a pan to really get it as flexible as possible, if that fails I'm going to slice it, thereby opening up the diameter. Once it's in the shock absorber top mount ring and compressed it won't make any difference. Discovery 4 HSE
1998 110 TUM HS FFR Hard Top XD WOLF
1982 Series 3 Hard Top

*Gone:L462 D5 HSE LUX, L663 Defender 110 HSE, Discovery 3 HSE, 2014MY Range Rover Sport 5.0 Supercharged AB Dynamic; L405 Exec Vogue SE 4.4, 5.0 Supercharged Autobiography, Defender TDCi XS CSW, Defender TD5 HT, Vogue SE TDV8, Vogue TD6, RRSport SC 4.2V8, Classic 3.9 Vogue Auto, Land Rover Series 3 SWB

I think bellini may be right with his comments about the upper shock mount. quite often to deal with the longer suspension travel, the shock would be physically longer, and require a different upper mount bolted to the chassis, not unreasonable to think that this is a different diameter.

Is it that the bush wont slide over the mount cause the diameter of the mount is too large, or that the length of the mount cant take both sides of the bush and the bolt on the end to hold it in place. V8 or else ...