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I got a new brass output pilot bushing, as the old one was quite worn and had a lot of play when the output pilot shaft was inserted. Once I got the new one it fit perfect with the shaft (outside housing). I froze the bushing and heated the shaft and carefully press on with a bearing press. All seemed great BUT now the output shaft does not slide in. What to do.....

That is common. When you squeeze them the inner hole gets smaller. Now you need to size that inner hole to your input shaft. Depending on the amount of wear on your input shaft you may have a wee bit of reaming to do or a lot of reaming to do. Don't make it too big! You are looking for a slip fit.

To learn more about the differences between Interference/press fits and slip fits download and use this guide:
http://www.webpages.uidaho.edu/mindwork ... ancing.pdf

Thx Wes,
Good to hear it's a common issue.

Are you sure they were brass? They are usually a oil impregnated bronze. They even normally are to be soaked in oil before installation.

oh...I say brass but you are probably right, it's bronze. It is Part number 936448. From QTM Parts. The Novak video didn't mention soaking it in oil, that might have helped. Oh, well, I will ream it in carefully. It's close as it stands.

When you ream, actually use a reamer. Don't try an abrasive route, it will impregnate grit into the soft bronze.