Problem removing broken front torsion bar

alfisti · 07-19-2015, 03:37 AM

(making a new thread for this so it will be seen)

'87 Carrera coupe

One of the front torsion bars snapped on Friday morning. The timing is a bummer because I need to bring the car in to the body shop Monday morning. :-( I was able to find a replacement bar locally on Saturday. Now I'm having trouble removing the old one. This was discussed in this thread: ack! What broke?!?!

I was able to get the cap off - and it did, in fact spin freely, indicating a broken torsion bar.

Once I got the rear cap off, I was able to remove it with the broken end. The thing snapped right in two, about 3-4 inches from the back.

Where I'm stuck now is, I can't get the rest out. I read about removing the dust cap in the front, and tapping it through from the front to the back. But I am having a bear of a time removing the dust cap! I broke off a drill bit, but was able to make a hole. I pushed a punch through and tried to pry it off, and it just broke the punch. In fact, I broke one punch, and turned the other into something that looks like a dental instrument.

Any tips on getting it off? I feel like I'm THIS CLOSE

Thanks
-Glenn

Dan J · 07-19-2015, 04:12 AM

How big a hole and punch? Drill a 1/2" hole and use a big punch
You're on the right track

SiberianDVM · SiberianDVM's Garage

^^
This. Drill a decent sized hole. When you are done you can fill the hole with a metal or rubber plug. You don't have to remove the plug completely, just use a big punch through the hole onto the end of the TB and BIG, heavy, short handled sledge or dead blow hammer.

alfisti · 07-19-2015, 06:52 AM

Thanks. I will give it a try tonight when I get back.

jpnovak · 07-19-2015, 07:03 AM

1. remove front torsion bar cover cap. This is the forward most bolt of the three used near the front collar. 1 is the protective cover. The other two are the front a-arm collar.

2. Use a large drift to push the torsion bar forward. This will press out the front end cap on the end of the a-arm. It should come out quite easily. However, it will not be able to come out of the a-arm. You only want to remove the cap.

3. once end cap is removed use drift to push torsion bar out the back.

4. replace cap. It will press into the end of the a-arm.

5. Insert new a-arm.

6. Prepare to quickly replace all the front (and most likely rear) suspension bushings. They are shot. The #1 cause of a broken torsion bar is a collapsed bushing that allows the torsion bar to rub on the inside of the a-arm. This rubbing creates a weak spot and eventually breakage.

patz · 07-19-2015, 01:24 PM

Don't forget to have it aligned after replacement.

alfisti · 07-19-2015, 03:46 PM

OK, going a LOT better now. The bigger hole worked, I whacked that sucker from the front, and it came right out! -almost. The sway bar is in the way.

Is the sway bar under tension with the car up, and the suspension at full droop? If I undo the fasteners, can I drop the sway bar out of the way? Car is an '87 G50 car, looks like oil lines around it as well. I need more clearance. Is there another trick to this?

Thanks
-Glenn

alfisti · 07-19-2015, 03:58 PM

p.s. you folks have been hugely valuable, REALLY appreciate your tips!

alfisti · 07-19-2015, 04:00 PM

Das Schnell Ei · 07-19-2015, 04:04 PM

rusty bar..

alfisti · 07-19-2015, 04:06 PM

the sway bar? Yes, I was thinking the same thing. :-(

Just going farther down the rabbit hole....

Lots to deal with after the body work. Right now - need to just get it on the road for the body work.

Any other tricks to clearing the sway bar? Just unbolt it and move it out of the way?

zippy_gg · zippy_gg's Garage

An option would be a cutting wheel so you can bring the bust TB down to size and have enough clearance to pull it out.
The line in the way is likely an AC hose, so careful around it.
Last resort would be to remove the anti-swaybar bracket on the side affected. No big deal; I think you've accomplished the hardest part already!

alfisti · 07-19-2015, 04:08 PM

cutting the old one will help me get it out - but I still need to put the new one in... so I guess I have to move the sway bar out of the way.

Thanks
-Glenn

azhodge · azhodge's Garage

Das is referring to the rusty torsion bar. that is most likely why it snapped. make sure you liberally coat the new one with grease.

zippy_gg · zippy_gg's Garage

I forgot about installing the "new" TB...
So yes on removing the sway bar bracket.
no need to grease the TB since you are just driving to the shop.

alfisti · 07-19-2015, 05:07 PM

Got it out!!!! THANKS folks!!!

ALMOST done - just having trouble seating the new one. I greased it, and slid it in - but it doesn't want to seat properly on the splines. Any trick to this? Just whack it till it pops on? Even on the cap I need to pop onto the end - doesn't go in easily.

Thanks
-Glenn

alfisti · 07-19-2015, 05:30 PM

zippy_gg · zippy_gg's Garage

Before I re-installed mine I thoroughly cleaned the old grease and/or rust from the splines and then applied new grease and new seals.
Still I had to use a mallet and wacked on a small piece of lumber to seat the TB on the passenger side.

alfisti · 07-19-2015, 06:10 PM

well I brushed both ends, greased carefully, and even brushed the inside end of the front of the A-arm. I am beginning to wonder, are there more than one size torsion bar ends? I mean, I whacked this thing in, and in went in far enough that I couldn't pull it out - so I opened the front again, and banged it back out the front.

Even the cap on the rear (with the adjusting screw) doesn't want to go on.

am I nuts??? This thing just won't go on.

Thanks
-Glenn

alfisti · 07-19-2015, 07:08 PM

are 914 torsion bars the same part? reminder: I have an '87 Carrera. The new bar I got has "914" written on it in magic marker. And I can't get it to fit. So... maybe this is the wrong bar :-(