Astro, Safari 1997-2005

Torsion Bar

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Removal & Installation



Instead of the coil spring used on the front suspension of 2WD vehicles, the 4WD vehicles are equipped with a torsion bar.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen adjustment assemblies on the torsion bar.
  4.  
  5. Mark the adjustment bolt setting.
  6.  
  7. Use tool J-36202 to increase the tension on the adjustment arm.
  8.  
  9. Remove adjustment bolt and the retaining nut, then move the tool aside.
  10.  
  11. Remove torsion bar adjustment arm by sliding the bar forward.
  12.  
  13. Slide the torsion bar partially back through the crossmember.
    NOTE
    The front end of the torsion bar are marked with a left and a right because there are different bars for both sides.

  14.  
  15. Lower the front of the torsion bar down and slide it forward.
  16.  

To install:

  1. Lubricate the adjuster arm and the bolt with axle grease.
  2.  
  3. Install or torsion bar adjuster arm. The rear face of the torsion bar should be within 0.04-0.10 inch (1.0-2.0 mm) of the rear face of the adjuster arm when both are fully installed.

    Click image to see an enlarged view

    Fig. The rear face of the torsion bar should be within 0.04-0.10 inch (1.0-2.0 mm) of the rear face of the adjuster arm when fully installed

  4.  
  5. Install adjustment retaining nut and the adjustment bolt. Using tool J-36202, increase the tension on the torsion bar
  6.  
  7. Install retaining nut and adjustment bolt.
  8.  
  9. Place the adjustment bolt to the marked setting.
  10.  
  11. Use tool J-36202 to release the tension on the torsion bar until the load is taken up by the adjustment bolt, then remove the tool.
    1. Check the Z height on rear wheel drive models as follows:
    2.  
    3. Lift the front bumper of the vehicle up about 1.5 inch (38 mm) and then remove your hands.
    4.  
    5. Let the vehicle settle.
    6.  
    7. Repeat the previous steps twice until you have lifted the bumper 3 times.
    8.  
    9. Measure from the lower control arm pivot bolt center line down to the lower corner of the steering knuckle.
    10.  
    11. Find the average of the high measurements and the low measurements in order to determine the Z height dimension.
    12.  
    13. Check the Z height on rear wheel drive models as follows:
    14.  
    15. Lift the front bumper of the vehicle up about 1.5 inch (38 mm) and then remove your hands.
    16.  
    17. Let the vehicle settle.
    18.  
    19. Repeat the previous steps twice until you have lifted the bumper 3 times.
    20.  
    21. Measure from the lower control arm pivot bolt center line down to the lower corner of the steering knuckle for the Z height measurement.

      Click image to see an enlarged view

      Fig. Z height measurement-4WD

    22.  

  12.  

 
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