With the use of a 3/8" drill bit and a 1-5/8" hole saw, this job is simple and quick. To remove these bushings, many poly bushing instructions recommend 'walking' a 3/8" drill bit around the bushing between the bushing and the shell. Walking the drill bit around the bushing invariably results in large chunks of the bushing still being bonded to the shell once the even the 'core' of the bushing is drilled out. Removing these chunks of rubber is generally where the frustration begins and the project becomes tedious.
However, a 1-5/8" Red Devil hole saw just happens to be the perfect size for cleaning up the bore of the shell, including removing any chucks of the bushing still bonded to the shell. Use a little spray lubricant on the hole saw. The hole saw will slightly shave the inner surface of the shell. The minimal amount of material removed from the shell does not adversely affect the fit of the poly bushing within the shell.
On '94 and older stangs, be sure to temporarily relocate the brake flex-line junction block located adjacent to the driver's side diff ear bushing prior to drilling.
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