Rear Torsion bar cover problems....

911Brian · 911Brian's Garage

I am in the process of putting my right rear suspension back together and am unable to get 2 of the bolt holes lined up with the body on the torsion bar. I had a very tough time getting the top 2 in. It is number 35 in the pic

Should I not drive it until these two are in?

Zeke · 09-19-2004, 05:37 PM

Why aren't they lining up? Same plate, same car? You might put some pressure on the plate with a jack to align th holes, but I would first want to know why. You will be binding the bushing and me thinks it will want to start squeaking.

911Brian · 911Brian's Garage

Yup same plate same car. I actually used the jack to line up the second hole. It is off by about 1.5 - 2 mm.. enough to not allow the bolt to catch the threads....

Neilk · 09-19-2004, 08:20 PM

Undo all the bolts and take off the cover. Go to the hardware store and get 4 really long bolts and 4 medium sized bolts that have the same thread and pitch and the regular bolts (#37). Now slowly screw the cover on using the long bolts and then switch to the medium bolts when those fit. Everything should line up. I know it a pain to take everyting apart, but it should work.

Randy Webb · 09-19-2004, 09:01 PM

Maybe something is not centered and that is keeping the cover from lining up right?

mtelliott · 09-19-2004, 09:07 PM

Neilk said it best. That's the way to do it. It's the only way to make sure you pull it down properly.

911pcars · 09-19-2004, 11:12 PM

That cover should just slip on. Something is in the way. Is there any vehicle weight on the suspension? Unbolt the spring plate from the control arm. See if there was some misalignment there that caused something to tweek.

I wouldn't use any force to install the cover - that includes longer bolts to draw the cover on. Find out why it's not aligned.

Sherwood

filo · filo's Garage

Hey I have a question about that same cover plate.
I was under my car yesterday and noticed cracks in the cover plate. Is this something that should be handled right away? Or can I wait until I do the rest of my suspension upgrades?

911Brian · 911Brian's Garage

Quote:

Originally posted by Neilk
Undo all the bolts and take off the cover. Go to the hardware store and get 4 really long bolts and 4 medium sized bolts that have the same thread and pitch and the regular bolts (#37). Now slowly screw the cover on using the long bolts and then switch to the medium bolts when those fit. Everything should line up. I know it a pain to take everyting apart, but it should work.

I will give that a try. The inside of the cover where the bushings rest had some type of extemely hard crud in it. I did my best to chisel it out. I don't know if that has anything to do with it. I can't see where the cover is bent in any way.

911Brian · 911Brian's Garage

Quote:

Originally posted by 911pcars
That cover should just slip on. Something is in the way. Is there any vehicle weight on the suspension? Unbolt the spring plate from the control arm. See if there was some misalignment there that caused something to tweek.

I wouldn't use any force to install the cover - that includes longer bolts to draw the cover on. Find out why it's not aligned.

Sherwood

It is probably that "crud" I mentioned a post ago. I may just have to get a a new cover.

john70t · 09-20-2004, 05:24 AM

Try grinding and sanding the inner cover surfaces to a smooth finish. That's a necessary step everytime.
And check that both holes are round.
The bushing is going to have a slight interference fit, but it should be even all the way around so match the surfaces up before pressing it in.
My suggestion would be to sand(light grit) a bevel on the bushing edge and use a temporary lube such as a very light coating of soap.

911Brian · 911Brian's Garage

Quote:

Originally posted by john70t
Try grinding and sanding the inner cover surfaces to a smooth finish. That's a necessary step everytime.
And check that both holes are round.
The bushing is going to have a slight interference fit, but it should be even all the way around so match the surfaces up before pressing it in.
My suggestion would be to sand(light grit) a bevel on the bushing edge and use a temporary lube such as a very light coating of soap.

I tried that. I worked and worked on that crud for a while with a wire brush wheel and got nothing but sparks. It is HARD stuff. I don't even know what it is....

Rot 911 · 09-20-2004, 05:35 AM

It is rock hard rubber that has migrated from the bushing to the cover. I used sandpaper to clean out the covers.

fireant911 · 09-20-2004, 05:36 AM

filo,
Are you certain the cracks are in the cover or on the welds to the body as shown in the link below?

Rear Suspension Broken Weld Question

911Brian · 911Brian's Garage

Quote:

Originally posted by Kurt V
It is rock hard rubber that has migrated from the bushing to the cover. I used sandpaper to clean out the covers.

What grit paper did you use? I was trying to pick at it with a screwdriver and the stuff would hardly budge!

Zeke · 09-20-2004, 07:42 AM

You could use a drill mounted drum sanding attachment, but covers are cheap used.

juanbenae · juanbenae's Garage

i had the same problem. if the plate does not go on perfectly strait the holes wont line up. i just started each bolt a bit. then i was able to move the plate around with a rubber mallet to get them to line up. the trick is to leave them as loose as you can until you get all four bolts started.

Jdub · 09-20-2004, 10:32 AM

This is very typical. Don't force anything: if you crossthread those internal threads you will be sorry.

Heat the cover and chisel it all out - every bit. Buy a sanding drum of 200 grit, then 400 grit and start with the coarse one. Get it round again. Then smooth it with the 400.

Buy the bolts if the above doesn't work. Alternative is to file the holes i the plate a bit oblong: cheap fix but not the best suggestion.

Best of luck,
John

911Brian · 911Brian's Garage

Quote:

Originally posted by Jdub
This is very typical. Don't force anything: if you crossthread those internal threads you will be sorry.

Heat the cover and chisel it all out - every bit. Buy a sanding drum of 200 grit, then 400 grit and start with the coarse one. Get it round again. Then smooth it with the 400.

Buy the bolts if the above doesn't work. Alternative is to file the holes i the plate a bit oblong: cheap fix but not the best suggestion.

Best of luck,
John

I will try all of the above. I am terrified of crossthreading those things. I am very carefull. I am sure I can get it all on there... I just had enough and had to walk away before I did something real dumb...

911pcars · 09-20-2004, 10:59 AM

If you insist on using force, try this. Insert a tapered drift punch through one of the torsion bar cover holes and into one of the threaded holes, maybe one of the lower holes, then use the punch as a lever to align the holes. Make sure the threads are clean and not damaged so you can thread the bolt by hand.

Hope this helps,
Sherwood