HI Matt,  Removing and replacing air motor bushings only looks
difficult.  The real trick is learning how to remove and replace
the connecting rods.  Here are the steps.

After removing the cam and connecting rods (as one unit) from the
motor, do a quick cleaning of the cam (the exposed areas) with any
product similar to steel wool, to remove as much of the gunky buildup
as possible*.  Don't be too concerned about the small scratches you
might make in the cam, you'll be polishing it before you begin the
assembly process.

*You can also use a good metal cleaning polish.  The point is to get
the bends in the cam fairly clean.  Forcing the bearing around a dirty
corner requires considerably more effort, which can lead to breakage.

Now, mark each connecting rod so you won't mistake where it came from.
This step is absolutely necessary since it is extremely common for the
flange screw holes and the flange 'break-off' pattern to be different
from piece to piece.  Don't leave it to chance.

The real trick to removing the connecting rods without cracking them
at the bearing hole is to orient them such that the flanged end of the
rod is on the same side as the longest part of each bend.  Kind of like
taking the 'longest-way-around' the corner.  As you round the corner,
wiggle the flange-end of the rod up and down (in a plane perpendicular
to the bend) slightly.  Continue 'working' the rod around the corner
until it reaches the next straight part.  Now re-orient the rod for the
next bend and begin again.

Naturally, you want to take the shortest route from each connecting
rod to the outermost part of the cam.  So connecting rods 1 and 2 are
removed to the left and 4 and 5 are removed to the right (or visa-
versa).  No. 3...  well, that's your call.

Once the rods are off the cam, take a sharp, pointed knife and gently
work the bushing out of the rod.  You'll find they come out rather
easily.  Save a couple of them for sizing the new strip of bushing
cloth.  Now finish polishing the cam and then give it a very thin
coating with Marvel Mystery Oil.

After installing the new bushings, reverse the disassembly process.
(Apply a small dot of glue to the flange before mounting.)

A copy of the above procedure, with a diagram, can be found at:

    http://www.player-care.com/rods_off.html
   (diagram at: http://www.player-care.com/gifs/rods_off.gif)

For the procedure I use to install the new bushings/w diagram, read
the webpage at:

    http://www.player-care.com/new_bush.html
    (diagram at: http://www.player-care.com/gifs/new_bush.gif)

Musically,

John A. Tuttle (john@player-care.com)
Visit the website: www.player-care.com

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