I just removed the bushing from my steering box side cover, and I'm so excited by how easy it was that I wanted to share it with all who are interested. I was anticipating a nightmare of cutting with a saw blade and smashing with a punch but I didn't have to. Basically the concept is to bind a solid piece into the bushing with screw threads so that it can be pounded out from the other side. Here's what I did:
I took a piece of round steel bar stock 1" in diameter, (exact dimension isn't terribly critical but you don't want too much space between the steel and the sides of the bushing). I cut it with my angle grinder & cutting wheel so that it fit inside the bushing and was roughly flush with the top of the bushing. Then, with the grinder I cut 2 slots parallel with the length of the bar (roughly 1/16" deep and 1/16" wide) in order to provide a channel for the screws to lock in to, (3 slots may work better for more grip). I used a cordless drill to evenly torque sheet metal screws into the slots/bushing. The threads cut into the bushing and bound the bar stock tightly. Then I took a huge nail with the point cut off that I use as a drift and put it through the threaded hole in the cover side and tapped away. The bar slipped out the first time, but after retightening the screws, the bushing came right out-and there was no damage to the bore of the cover.
The beauty of this is that you don't need any specialized tools. If you don't have the bar stock, you can probably use a 1" bolt and do the same thing. They sell up to 1" thick bolts at OSH. If this description is not clear let me know and I can take a picture of the piece I fabricated.
