Torsion Bar: Service and Repair

REMOVAL

Fig. 6 Hydraulic Jack Positioning Point:

1. Raise and support vehicle.
CAUTION: Do not support vehicle weight under V-shaped channel on axle. Axle weight must be supported at point A, using a suitable jack.
2. Remove both rear wheel and tire assemblies.
3. Remove rear shock absorbers as previously described.

Fig. 7 Anti-sway Bar Protective End Caps:

4. Remove protective caps (A) and (B), from both sides of vehicle.
5. Remove clips from ends of suspension and anti-sway bars using a suitable screwdriver.

Fig. 8 Lower Control Arm Reference Marks:

6. Note alignment mark D, on suspension bar mount and make a reference mark (position E) on lower control arm as shown.

Fig. 9 Torsion Bar Reference & Location Marks:

7. Note and record positions of marks G, on all four torsion bars relative to marks D and E. Location of marks on torsion bars (position G) will vary depending on application.
8. Lower rear axle, then pull suspension bars using a suitable slide hammer until splines disengage.
9. Pull anti-sway bars out using a suitable slide hammer.
CAUTION: The rear axle assembly will be damaged if a load is applied to jack supporting the axle.

Fig. 10 Axle Attaching Bolt Locations:

10. Support axle at point L, then loosen bolts (M) approximately four turns and bolts (N) approximately ten turns.
11. Lower jack until axle has dropped approximately one inch.
12. Remove suspension bars, then the torsion bar connecting link from vehicle.

INSTALLATION

1. Install torsion bars into rear axle.
NOTE: Do not engage splines at this time. Ensure torsion bars are installed in original position.
2. Raise axle and torque rear axle mounting bolts to specifications.

Fig. 11 Axle Spacing Tool Position:

3. Position rear trailing arms as follows:
a. Adjust dimension X, on each of two tools Sus.Lm.02 to 17-15/16 inches.
b. Loosely install bolt (C) and spacer (A) from tool set No. T.Ar. 1056 into rear lower shock absorber mounting hole.
4. Apply a suitable lubricant to torsion bar splines and install torsion bars in original position. Ensure recorded marks G, D, and E are properly aligned to avoid added stress to bars.
5. Use recorded marks to position anti-sway bar G into mounting.
6. Install connecting link to splines of anti-sway bar G. Ensure connecting link is centered in V-shaped channel in axle.
7. Install anti-sway bar D in outer mounting and secure in connecting link.
8. Install both suspension bars through outer mounting and secure in connecting link.
NOTE: Ensure all torsion bars are installed in original position. If splines are difficult to engage, slightly twist link as necessary using suitable pliers on the connecting link.
9. Remove threaded rod tools from vehicle, then install shock absorbers.
10. Install clips and protective caps on end of torsion bars.

Fig. 12 Torsion Bar Spline Dimensions:

11. Center torsion bars in mountings as follows:
a. Tap ends of suspension bars until outer end of bar protrudes 3/4-7/8 inch from outer edge of mount on both sides, using a large brass drift.
CAUTION: Do not hammer directly on torsion bar splines.
b. Tap ends of anti-sway bars until outer end of bar protrudes 3/16-5/16 inch from outer edge of mount on both sides.
CAUTION: Do not hammer directly on torsion bar splines.
12. Install wheel and tire assemblies.