GM Astro/Safari 1985-1996 Repair Guide

Torsion Bars and Support

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Certain procedures in this guide, including torsion bar removal and installation require that you first UNLOAD the torsion bar. This is accomplished using a special unloading tool such as J-36202 or equivalent. If you are performing service on another part of the vehicle, that first requires the torsion bars to be unloaded, refer to that portion of the torsion bar removal and installation procedure in this section and perform the necessary steps as outlined.

REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Torsion bar unloading tool



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Fig. Fig. 2: Exploded view of the torsion bar mounting-1990-92



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Fig. Fig. 3: Exploded view of the torsion bar mounting-1993-96

  1. Disconnect the negative battery cable for safety.
  2.  
  3. Raise and support the front of the vehicle safely using jackstands.
  4.  
  5. Mark and unload the torsion bars:
    1. Mark the adjustment bolt setting on the bolt adjusters.
    2.  
    3. Increase tension on the adjustment arm using the unloader tool J-36202, or equivalent.
    4.  
    5. Remove the adjusting bolt and retainer plate.
    6.  
    7. Move the tool aside.
    8.  

  6.  
  7. For 1990-92 vehicles:
    1. Slide the torsion bar forward and remove the adjustment arm.
    2.  
    3. Remove the nuts and bolts from the torsion bar support-to-crossmember. Slide the crossmember rearward.
    4.  
    5. Mark the location of the front and rear ends. Mark either left or right because the bars are different.
    6.  
    7. Remove the support crossmember, retainer, spacer and insulator from the crossmember.
    8.  

  8.  
  9. For 1993-96 vehicles:
    1. Remove the torsion bar anchor adaptor by sliding the adapter out toward the rear, then removing the adjustment arm.
    2.  
    3. Note the location of the tape or painted stripe at the rear ends of the torsion bar (since there are different bars for the right and left sides), then remove the torsion bar from the vehicle.
    4.  

  10.  

To install:
  1. For 1993-96 vehicles:
    1. Note the location of the tape or painted stripe at the rear ends of the torsion bar and position the bar to the vehicle. Remember that there are different bars for different sides of the vehicle and the tape or paint should be located to the rear.
    2.  
    3. Install the bar anchor adaptor, by positioning the adjustment arm, then sliding the adapter tube over the torsion bar and adjustment arm.
    4.  
    5. Make sure the adapter tube is properly seated into the front face of the crossmember. Make sure the torsion bar is properly seated into the rear of the adapter tube against the stop tabs.
    6.  

  2.  
  3. For 1990-92 vehicles:
    1. Install the insulator, spacer and retainer onto the support crossmember.
    2.  
    3. Install the crossmember onto the frame, rearward of the mounting holes.
    4.  
    5. Make sure the bars are on their respective sides. Slide the crossmember forward until the bars are supported.
    6.  
    7. Install the adjustment arms, crossmember bolts and nuts. Torque the center nut to 18 ft. lbs. (24 Nm) and the edge nuts to 46 ft. lbs. (62 Nm).
    8.  

  4.  
  5. Properly tension and adjust (as necessary) the torsion bar:
    1. Increase the tension on the torsion bar using the unloader tool.
    2.  
    3. Install the adjustment retainer plates and bolt.
    4.  
    5. Set the adjuster to the position marked during removal.
    6.  
    7. Release the tension on the bar until the load is taken up by the adjustment bolt, then remove the unloader tool.
    8.  

  6.  
  7. Remove the jackstands and carefully lower the vehicle.
  8.  
  9. Check and adjust the "Z'' height as outlined in the alignment information later in this section.
  10.  

 
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