Issues with Powerflex wishbone bushes

[DanielG]

This requires a bit of a back story - back in December I got a set of the Powerflex wishbone bushes fitted by a suspension 'specialist' who argued with me the sleeves needed no welding - sure enough, 2 days later on track, the sleeves had popped out and were ruined.

They decided to repair the sleeves by straightening them out and trying again, but this didn't work and it was found the wishbone was still flexing a lot due to the metal being softened. I contacted Powerflex to get their opinion on this matter and they sent me a new set of bushes with modified sleeves despite not being at fault.

This time the set was fitted correctly with the sleeves tack welded in etc... so after 2 months of street driving, this is what the rear left wishbone bush looks like...



Rear Right:




Basically my question is - WHY is this happening? Powerflex have been absolutely FANTASTIC in trying to sort this out for me but they have no idea why this is happening - they've never seen it before. It appears the wishbone is flexing far too much under braking, but I don't see why this would be a unique issue if that was the case. Also I don't quite get why the left side is significantly worse.

If anyone has any ideas as to the possible reason behind this, I'm all ears (and I'm sure Powerflex are too!). Once again, I have to give them a massive thumbs up. They're trying their best to sort it out for me and are sending me a set of bushes made from one of their firmed materials (Black 95) to see if this helps.

[ROB91]

I suffered with a similar problem with the sleeved becoming deformed and the bushes damaged, that was put down to the first lot of tack welding being poor.

[DanielG]

I don't quite see how the tack welding could be at fault here though, the sleeves themselves aren't moving at all, it's the entire wishbone that's flexing.

[martin182]

Hence Why OEM bushes are fine! they flex under pressure unlike powerflex which results in the eating of bushes

[DanielG]

Hence Why OEM bushes are fine! they flex under pressure unlike powerflex which results in the eating of bushes

I don't get it. My issue is exactly that - they're flexing too much.

[!sean172!]

Totally changed my mind about getting some of these now

[DanielG]

Totally changed my mind about getting some of these now

I don't know if you should be. I've never read of anyone else having this sort of issue and Powerflex are baffled by it as they've never seen it before either :/

[!sean172!]

Strange why it's happend tho if they're so highly rated . Just seems like ball ache having to change them again if this is happening. Do they have to pressed out to be fitted?

[Matt e]

I've had mine on for nearly 2 years now and mine are fine, maybe something happened to the wishbone the first time you had them fitted without being welded into place?

[Silent_Scone]

most if not all the issues with these bushes from what I've read have been down to incorrect fitments i.e wrong orientation or not enough weld. Although the fact that one side has completely perished would make you wonder whether theres another underlying issue with your suspension on that side

[DanielG]

most if not all the issues with these bushes from what I've read have been down to incorrect fitments i.e wrong orientation or not enough weld. Although the fact that one side has completely perished would make you wonder whether theres another underlying issue with your suspension on that side

The thought of an underlying issue has come up - but the alignment was all spot on when they were first fitted (it's only deteriorated with the bush). I'm all out of ideas unfortunately. The orientation looks correct and I don't think the issue lies with the welds either as the sleeve isn't moving (as it did in the first place when it wasn't welded at all)

[Fred@BTM]

fitment is the issue there, they've been fitted with too much bush poking out of the sleeve IMO

[Dan@519Automotive]

can see in the 2nd pic that the sleeve has moved despite the weld (which is nowhere near enough btw)

the sleeves are chewing up the bushes as they're moving around (IMO)

[Fred@BTM]

oh and if those are your rear bushes on the wishbones the bolts are the wrong way round too, they should face the front of the car

[Dan@519Automotive]

fitment is the issue there, they've been fitted with too much bush poking out of the sleeve IMO

and that too. Generally just not fitted right

[DanielG]

fitment is the issue there, they've been fitted with too much bush poking out of the sleeve IMO

Interesting - how would you avoid this? The sleeve is sitting correctly within the wishbone (Powerflex modified the sleeve around to ensure there is *no* way it will slip out of the wishbone)

can see in the 2nd pic that the sleeve has moved despite the weld (which is nowhere near enough btw)

the sleeves are chewing up the bushes as they're moving around (IMO)

The sleeve's have more than just one tack weld on them (they have 4). I honestly don't think the sleeve is shifting, I think the entire wishbone w/ sleeve is shifting around the bush.

Interesting on the bolt - I've got a friend coming around with their stock 172 today so I'll have to take a look and see what it's like.

[Fred@BTM]

the sleeves are pressed too far into the wishbones, they have to be almost touching the subframe is what i'm saying

were the bolts torqued? was the car in the air when they were tightened or on the floor (well with the suspension under load anyway)

[Dan@519Automotive]

Red area highlights where there is evidence of the sleeve moving
Blue area is where the weld should be penetrating all the way along

[Jaff.]

Crap! Need mine welded up more then! How do you know the correct position for the sleeve then?

[DanielG]

the sleeves are pressed too far into the wishbones, they have to be almost touching the subframe is what i'm saying

were the bolts torqued? was the car in the air when they were tightened or on the floor (well with the suspension under load anyway)

I have no idea if they have been torqued - this was all done by a workshop. Since I'll be doing the next set myself - what should they be torqued to and should they be tightened under load?

Not sure what you mean about the sleeves being pushed in too far - they sleeves are pushed in from the inside of the wishbone, not the side we can see in the photos. So they can't come any closer to the chassis.

Red area highlights where there is evidence of the sleeve moving
Blue area is where the weld should be penetrating all the way along

Not sure if the red area is actually the sleeve moving - I'd have to have a better look at it.