Pilot bushing seems oversized.

bocaj138 said:

I am installing a clutch kit from McLeod which comes with a standard pilot bushing .941” OD. I removed an old pilot bushing which I had to chisel and break out because it was completely flush towards the crank end and none of the other methods worked. While comparing a piece of the old bushing I noticed the sidewall of the old bushing looked thinner, but I assumed possibly from wear. I try to install the new bushing and there is absolutely no way it’ll fit. The new bushing measured .935 OD, I measured ID of my crank best I could and it seemed closer to .88” five or take. Anyone run into this problem? I can’t find anything about an alternative bushing.

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Vaanth said:

Crankshafts in pre-Magnum style Chrysler engines could be un-drilled, drilled but not finish reamed, or finish reamed to size. The pilot bushing was installed in the finish reamed crankshafts if intended, or potentially intended, for manual transmission use.

The original Chrysler Oilite pilot bushing, part number 53298, has an outer diameter of 0.941 inch. The bushing is a light (0.003") press fit in the drilled and finish reamed hole. The bushing is also available on the aftermarket, including Pioneer PB286/PB286HD, SKF B286/B286HD, Federal Mogul/Precision PB286HD, Timken PB286HD, and previously NAPA 615-1026.

The drilled, but not finish reamed, hole is ~0.914 inch. Chrysler did not provide a bushing for this hole size as they intended it to be finish reamed to the proper bushing size. However, the aftermarket produced a bearing in the drilled only hole size. This size bushing was available as NAPA part number 615-1033. This number is apparently discontinued though, but might still be found from other sources.

Al's Rapid Transit lists a replacement: Undersize pilot bushing

If your drilled hole is an even smaller size, it may have been drilled by someone and a bushing that fit was found for it.

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