Express, Savana, G1500, G2500, G3500, 1998-2005

Torsion Bar

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Special tool J-36202, or its equivalent, is necessary for this procedure.

  2.  
  3. Remove or disconnect the following:

    Wheels
     

  4.  
  5. Support the lower control arm with a floor jack.
  6.  
  7. Matchmark both torsion bar adjustment bolt positions.
  8.  
  9. Using tool J-36202, increase the tension on the adjusting arm.
  10.  
  11. Remove or disconnect the following:

    Adjustment bolt and retaining plate
     

  12.  
  13. Move the tool aside, and slide the torsion bars forward.

    Adjusting arms
     
    Torsion bar support crossmember and slide the support crossmember rearwards
     
    Torsion bars, matchmark the position. They are not interchangeable
     
    Support crossmember
     
    Retainer, spacer and bushing from the support crossmember
     

  14.  

To install:

  1. Install or connect the following:

    Retainer, spacer and bushing to the support crossmember
     
    Support assembly on the frame, out of the way
     
    Torsion bars, sliding them forward until they are supported. Align the marks made when removed.
     
    Support crossmember into position. Torque the center nut to 18 ft. lbs. (24 Nm), the edge nuts to 46 ft. lbs. (62 Nm).
     
    Adjuster retaining plate and bolt on each torsion bar
     

  2.  
  3. Using tool J-36202, increase tension on both torsion bars.
  4.  
  5. Set the adjustment bolt to the marked position.
  6.  
  7. Release the tension on the torsion bar until the load is taken up by the adjustment bolt.
  8.  
  9. Install both wheels

    Click image to see an enlarged view

    Fig. Installing the torsion bar-K-Series

  10.  


NOTE
This procedure requires the removal of both torsion bars.