Ok, well I stuck with the bushings that I had originally gotten, without drilling them out. So far so good, no tension rod breakage, but I haven't pushed it too hard cornering. The tail end has been thrown around a few times, but nothing major yet.
One problem I did run into was regarding the transmission. When my buddy and I did the swap, we took the bellhousing of the 240SX transmission and mated it up to the original 620 transmission, thereby not having to do any driveline modification or repositioning of the shift lever. Unfortunately, the old transmission didn't like a hard pull in 3rd and 4th (or maybe that's just when it decided to complain after some mild abuse over the previous weeks) and started making a racket. The following day, the sound from the transmission was almost unbearable. After work, we started driving the truck over to my buddy's shop and in the process 1st and 2nd were unusable, and I simply stuck it in 4th and hobbled along to get it to the shop. My buddy thinks that the countershaft bearing may have given up, and that was what was causing the noisy transmission, but then the drive to the shop may have compromised the countershaft or some other internal components (we haven't yet taken the transmission off and inspected it).
I have another co-worker who has a 2wd D21 hardbody 5-speed transmission that he doesn't need and is willing to sell it to me to help me get the 620 back on the road, but I'm unsure if the transmission will be a direct swap, or if I will need to do some additional work. Does anyone happen to know if the D21 5-speed will directly replace the 620 5-speed (it has a dogleg shift lever) without any additional modifications (longer/shorter driveshaft, shift lever relocation)? If not, would I just be better off trying to find a 240SX 5-speed transmission and bite the bullet to install that, cut the transmission tunnel to relocate the shift lever and then get a custom driveshaft made up?
Unfortunately I'm on a bit of a time crunch and need to get this all completed within the next week or so, as I'll be heading to Singapore for 5 weeks for work and I need to get the truck going before then so that it's not taking up my buddy's lift the whole time I'm gone, so I greatly appreciate some constructive feedback on this whole issue. I'm very much leaning towards the D21 transmission, as I've heard that it's about the same size as the 620's but if I can find out from someone who knows 100% if it will need additional work after swapping in the D21 tranny, then that is an immense benefit.
Thanks in advance!