GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Torsion Bar

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

REMOVAL & INSTALLATION



1994 Models

See Figures 1, 2, and 3

The following procedure requires the use of the torsion bar unloader tool J-36202 or equivalent.

  1. Raise and safely support the front of the vehicle safely using jackstands.
  2.  
  3. Install a torsion bar unloader tool to relax the tension on the torsion bar adjusting arm screw; record the number of turns necessary to properly install the tool. Remove the adjusting screw.
  4.  
  5. Move the torsion bar forward and leave it in place.
  6.  



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Fig. Fig. 1: Torsion bar front mounting-4WD front suspension



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Fig. Fig. 2: Use the torsion bar unloader to ease tension so the adjuster bolt may be removed

  1. Remove the adjuster arms.
  2.  
  3. Unfasten the nut and square washer (raise the support out of the way) from the retainer, then remove the retainer bolts from underneath the frame.
  4.  
  5. Slide the insulator off the support and remove it from the vehicle.
  6.  
  7. Disconnect the muffler flange from the converter, loosen the rear exhaust hanger and lower the rear exhaust.
  8.  
  9. Remove the torsion support from the frame.
  10.  
  11. Remove the torsion bars from the lower control arms.
  12.  

To install:


Click image to see an enlarged view

Fig. Fig. 3: Torsion bar and support mounting/alignment-1994 vehicles

  1. Position the torsion bars with the lower control arms. If installing a replacement component, be sure the tag is facing forward.
  2.  
  3. Install the support.
  4.  
  5. Install and secure the rear exhaust system to the proper height, then connect the muffler flange to the converter.
  6.  
  7. Install the insulator, making sure the mount studs are positioned through the support and the insulator locator tabs are indexed to the support (facing forward).
  8.  
  9. Install and finger-tighten the square washer and nut.
  10.  
  11. Install the insulator mounting retainers, then tighten the bolts to 26 ft. lbs. (35 Nm) and/or the nuts to 25 ft. lbs. (34 Nm).
  12.  
  13. Install the adjuster arms, then connect the torsion bars to the arms. With the torsion bars installed, check for an assembled clearance from the end of the bar to the support of 0.236 in. (6.0mm).
  14.  
  15. Lubricate the top of the adjusting arm and the adjusting bolt, then install the nuts and adjuster bolts.
  16.  
  17. Check and adjust the Z height as outlined in the wheel alignment section of this section.
  18.  

1995-99 Models

The following procedure requires the use of the torsion bar unloader tool No. J-36202 or equivalent.

  1. Raise and safely support the front of the vehicle safely using jackstands.
  2.  
  3. Remove the transmission shield, if equipped.
  4.  
  5. Install a torsion bar unloader tool to relax the tension on the torsion bar adjusting arm screw; record the number of turns necessary to properly install the tool. Remove the adjusting screw and the unloader tool.
  6.  
  7. Unfasten the lower link mount nut from one side, then disengage the torsion bars.
  8.  

Note the direction of the forward end and side of the torsion bar being removed

  1. Remove the lower link nut from the opposite side.
  2.  
  3. Remove the lower link mount, upper link mount nut, upper link mount and then unfasten the torsion bar from the frame.
  4.  

To install:
  1. Install the torsion bar and support.
  2.  
  3. Install the upper link mount and mount nut. Tighten the nut to 33 ft. lbs. (45 Nm) on 1995-96 models and 48 ft. lbs. (68 Nm) on 1997-99 models.
  4.  
  5. Place a jack under the torsion bar to release tension, then install the lower link mount bushing and nut. Tighten the nut to 13 ft. lbs. (18 Nm) on 1995 models, 50 ft. lbs. (68 Nm) on 1996-98 models and 37 ft. lbs. (50 Nm) on 1999 models.
  6.  
  7. Install the torsion bar unloader tool and tighten the tool against the adjusting arm the same number turns recorded earlier, then remove the tool. This loads the torsion bars.
  8.  
  9. Install the transmission shield, if removed.
  10.  
  11. Remove the jackstands and lower the vehicle.
  12.  
  13. Check and adjust the Z height as outlined in the wheel alignment portion of this section.
  14.  

 
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