I am installing a set of 4º offset c-bushings from Energy Suspension in my 79 Bronco and they are splitting out when I torque the caps together. The Dana 60 front has the ears welded on from a stock '79 9" and the size and angle match my stock axle exactly, which I kept unaltered to do the comparison with. I am drawing the cap down evenly to the arm in 1 thread increments, keeping the pressure equal as the cap meets the arm. All the bushings are marked "rear bottom" on one side which I have facing down on the arm side and "front bottom" on the other side which I have facing down on the cap side. After about two hours of installation they split and start creeping out of the sides of the radius arms (You can hear them splitting and moving!). My question is, what gives?!?!? I got the bushings from the guy who built the axle and they had been sitting on his shelf for a while in the factory shrink wrap. Do you think that these would become brittle after time? Am I missing something on the installation? Do I have the offset in the proper locations? Has anyone experienced this type of problem when installing them on a 9"? I have triple checked the measurements on both the 60 & 9" and they are the same. I am at a loss on this one and would really appreciate any feedback you all may have as to what the problem is. I tried to give all of the necessary info that you all would need but if I am leaving anything out, let me know. I have attached 4 pics of the bushings for evaluation. The full size pics are in my user gallery. Thanks all!
https://www.ford-trucks.com/user_gallery/displaythumbnail.php?&photoid=6006&.jpg https://www.ford-trucks.com/user_gallery/displaythumbnail.php?&photoid=6007&.jpg https://www.ford-trucks.com/user_gallery/displaythumbnail.php?&photoid=6008&.jpg https://www.ford-trucks.com/user_gallery/displaythumbnail.php?&photoid=6009&.jpg

 

I just noticed that I kept referencing a 9" front in my post. Please disregard my momentary lapse of reason. I meant to say a Dana 44 front, which I'm sure you all got. I just replaced the 9" REAR with a 14 Bolt and I think that is still stuck in my head. Sorry....

 

I hate replying to myself but want to conclude this post in the event someone uses a search regarding c-bushings. I finally got hold of the guy that made the axle and he said that he forgot to tell me that their were spacers in a big box of nuts and bolts that he gave me. I looked in the box and lo-and-behold there were four .600" spacers in the box. I put them on and the bushings look good. Now I have to order new bushings, keyhole the spring pad and spring retainer mounting holes, deal with a slight offset on the shocks and hope that the end buhings will forgive me and cut me a little slack. I think that's all I will be up against. Well, thanks anyways guys. Normally you guys are right on top of problems that have a "logical" answer. I wish this guy had just bored out the diameters of the ears to accomodate the bushings so spacers would not have to be used. I really don't want to take them off and turn them down at this point. Pic of the spacers in place.
https://www.ford-trucks.com/user_gallery/displaythumbnail.php?&photoid=6141&.jpg