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I melted out my front strut bar bushings and got ready to "pop in" the bushings. They didn't fit. I looked into getting another set from MR2 Club made by a different manufacturer thinking I had a screw up. I was lucky the parts guy has done this before. He said you need to remove the metal shell inserts that surround the old rubber bushing. NO ONE has every mentioned this in a posting I have read. So I cut them up with a dremel and a cutting wheel, popped them out, and popped in my new bushings.
The MR2 Club guy also said the front control arm situtation with the washer and sleeve being different but measurements on the outside of the set being right was a usual kind of redesign that is nothing to worry about. He said he was aware of this and he knew of people who left out the washer and things still worked fine...although I think it is a bad idea to leave them out intentionally.
Car is back to running and having no problems.
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