Issues with Sway Away spring plates not fitting torsion bars?
 

I am helping a friend refurbish his suspension.

There is a set of Sway Away rear spring plates to help aid setup compared to his early style stock, non-adjustable spring plates. However...

I can not get a torsion bar to slide into the outer section of the spring plate. Has anyone ever experienced this? I have tried several sets of torsion bars I have laying around and non of them fit. The torsion bar will go in approximately 2-3mm and then stop. Even a 5lb sledge could not insert a torsion bar. Its like they are just not cut right.

Any suggestions?

Are the G50 and 915 torsion bars have the same spline diameter? I know they have different lengths and the same teeth count. The spring plates are also considerably different shape. I am 99% sure these are the correct 915 style. I do not have any g50 parts to try them on.

This may be a dumb question, so apologies if it is. I don't have any experience with the SAW ASP, but I do have the ER ASP and SAW bars. Are you putting the bar in first and then trying to put the ASP over the end of the bar? I did it this way with polybronze bushings. In other words, if you took the ASP and the bar out of the car would the outer spline fit if you slide the plate onto the end of the bar vs trying to slide the bar into the plate?

I have the swayaways, and I inserted the torsion bar in the tube first, then put the spring plate on. Isn't that the way it's supposed to be done anyways?

I had to spend about two hrs. to dress each spring plate to match the t bars. I used a triangular file and a cf disc in a Dremmel. (mostly to cut the groves deeper and add some separation). It takes some time and patience.
What you don't want to do, is get them close in fit, then pound them home.
Bill K

Hi Jamie,

The G50 kit has a significantly longer tube for the splines. I have seen a number of comments about folks having to dress the splines in the plates with a triangle file to get the fit right. Let me know when you get home and I will come by with a set of files and help work these down and we'll see if we can get them to fit right.

Morrie

I'll come anD help as well. It's only my car, after all. Thanks guys for all the extra innings on this deal.��

I had to file mine in, it takes a couple of hours.

Dave

Had to work on mine too...tight. I called the sway a way owner and he said yada yada...it is obviously a cont. problem.
Once on they work fine and are an easy adjust.
Shouldn't have this issue tho.

Filing party at Jamie's. Jamie, text me when you are around and Bill and I will come help.

The problem is not technique. Replaced many suspensions on 911s. This problem is most definitely parts.

You are correct that you fit the torsion bar first and then the spring plate. its basically the only way.

I guess I have to decide if filing them down is the right thing or just spend the same amount of time to fit the stock spring plates (a few times) during corner balance.

Try filing first. When I did mine (SAW-SAW)
it was just a matter of dressing the splines. Very little material removed.

Spent some time carefully hitting each spline with a file. Tried a triangle and rectangular cut detail files and still no go.

Problem solved though. I switched out with some factory adjustable spring plates. Easy as expected.

Glad you got it done.....I just took a wire wheel to mine..I think the cad plating varies too much from batch to batch (Chinese?)

Glad you got it resolved. That's strange about the fitment issue, especially both being SAW products.

[QUOTE=jpnovak;8763735 Problem solved though. I switched out with some factory adjustable spring plates. Easy as expected.[/QUOTE]

You really didn't solve the problem. You're going to be very disappointed in the range and accessibility of the factory part. The sway-away plates adjust a full 2 - 3 inches by simply turning a 6mm Allen bolt without loosening or removing any of the 5 retaining/adjusting bolts.
Bill K

Bill,

The factory plates are not for adjusting ride height and neither are the SAW parts. It takes a little effort but adjusting ride height is done by indexing splines. Corner weight adjustments are done with the cam adjuster bolts.

You are right in the sense that I did not solve the problem of the SAW parts. But I did solve the problem of how to get the car back on the ground so I can move forward.

As you mentioned there might be more height adjustment without moving bolts. But changing ride height without moving those bolts can do bad things to the alignment. They have to move anyway.

YMMV