Sway-a-way Spline tolerance problem(?) with pics

[einreb]

Ive been trying to track down a noise issue on the left rear of my car after installing polybronze and new t-bars.

When I did the install, i was suprised at the visual differences at the outer diameter of the splines on the new left and right torsion bars. The right side would not go in the outer t-bar cover and we sanded it down (we swapped left and right to check, it wouldnt fit in either side). I wasn't sure i felt comfortable with how much I had to sand down the splines, but did the install anyway. I figure we took about 1/3 the height of the spline off and was still very snug when installed.

The left side slid in very easy and actually provided some rotational play when the polybroze was installed without the tbars. I got noise at the left side torsion bar cover location after the install.

I readjusted the polybronze (reshimming and adjusting pacers) 7 or 8 times. Each time I would try something different and each time the noise would go away for a day or two and then return. I had pelican send out replacement t-bars (they were very kind to do this considering it was 4 months after my initial purchase). Note, it was the 'smaller' t-bar side making noise and the reason for the return... but it would allow me to get a more correct right side tbar too where I wouldn't have sanded down splines.

I've dry fit the new t-bars and both are nice and snug. as opposed to one being 'loose' and one being tight. I'm also going to swap the polybroze left to right to see if the noise moves.

Anyone want to place any bets? Can a loose fitting t-bar make noise or will the noise move when i swap polybronze left/right?


Note right bar on left, left on right

[MotoSook]

Swapping the L/F BP bushings won't make for a good test. If you want to determine if the t-bars are problematic, you have to leave all else "fixed."

[einreb]

Originally posted by Souk
Swapping the L/F BP bushings won't make for a good test. If you want to determine if the t-bars are problematic, you have to leave all else "fixed."

Point taken. Actually, I should have swapped just the left t-bar instead of taking both sides completely apart. Crap.

Its my illogical attempt at trying to minimize the number of times I have to take this apart.

[450knotOffice]

My money is on the torsion bars...