Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Torsion Bars

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Torsion bars are used in place of coil springs on Pick-Ups and 4Runners. While employing the same torsional principal as a spring, the torsion bars are installed parallel to the ground instead of vertically as is a coil spring. This allows a much more compact suspension arrangement, lower front end styling and better suspension control since the torsion bar need not move through the greater distances traversed by a compression spring. The torsion bars are under tension as is any installed spring and great care must be taken when removing the bars.

REMOVAL & INSTALLATION



See Figures 1 through 12


WARNING
Great care must be taken to make sure torsion bars are not mixed after removal, it is strongly suggested that before removal; each be marked with paint, showing the front and rear of spring and from which side of the truck it was taken. If they are installed backward or on the wrong sides of the truck, they could fracture. New units are marked L or R with an arrow showing direction of flex.



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Fig. Fig. 1: Exploded view of the torsion bar suspension and associated components

  1. Raise the truck and support the frame on stands.
  2.  
  3. Slide the boot from the rear of torsion bar spring housing and onto spring.
  4.  



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Fig. Fig. 2: Slide the boot down the shaft at the rear of the unit



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Fig. Fig. 3: Matchmark the adjoining components

  1. Follow the same procedure on the front of the spring.
  2.  



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Fig. Fig. 4: With the aid of a small prytool, separate the boot from the torsion bar



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Fig. Fig. 5: Use paint to matchmark the front also

  1. Paint matchmarks on the torsion bar spring, anchor arm and torque arm.
  2.  
  3. On the rear torsion bar spring holder, there is a long bolt that passes through the arm of the holder and up through the frame crossmember, using a small ruler, measure the length from the bottom of the retaining nut to the threaded tip of the bolt and record this measurement.
  4.  



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Fig. Fig. 6: Loosen the long bolt that passes through the arm



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Fig. Fig. 7: Slide the bolt out of the arm



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Fig. Fig. 8: Measure the distance between the shoulder and the tip of the bolt

  1. Loosen the adjusting nut and remove the anchor arm and torsion bar spring.
  2.  



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Fig. Fig. 9: The bar should slide from the housing



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Fig. Fig. 10: When you remove the torsion bar, note that some models have markings for the left and right

  1. Remove the torque arm, there are tow nuts retaining it.
  2.  



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Fig. Fig. 11: Loosen these two nuts to remove the anchor arm

  1. Inspect all parts for wear, damage or cracks. Check the boot for rips and wear. Inspect the splined ends of the torsion bar spring and the splined holes in the rear holder and the front torque arm for damage. Replace as necessary. On the rear end of the torsion bar springs, there are markings to show which is right and which is the left bar. Do not confuse them.
  2.  
  3. To install the existing spring:
  4.  



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Fig. Fig. 12: Coat the splined ends of the torsion bar with multi-purpose grease

  1. Coat the splined ends of the torsion bar with multipurpose grease.
  2.  
  3. Align the matchmarks and install the torsion bar spring to the torque arm.
  4.  
  5. Align the matchmarks and install the anchor arm to the torsion bar spring.
  6.  
  7. Tighten the adjusting nut so that the bolt protrusion measured previously is equal to that of the new adjustment.
  8.  

  1. To install a new torsion bar spring:
    1. Install the 2 bolts to the torsion bar spring.
    2.  
    3. Lightly coat the spring end splines with grease and then install the anchor arm to the small end of the spring temporarily. Paint matchmarks on the spring and arm.
    4.  

  2.  

There is one spline on the spring that is larger than the others. When connecting the spring to the arm, turn the arm slowly until you can feel the larger spline match up with the slot in the arm.

  1. Remove the anchor arm from the spring and install the spring into the torque arm.
  2.  

There is one spline on the spring that is larger than the others. When connecting the spring to the arm, turn the arm slowly until you can feel the larger spline match up with the slot in the arm.

  1. Install the locknut and wheels, lower the truck and bounce it several times to set the suspension.
  2.  
  3. Measure the ground clearance and adjust with the adjusting nut. Tighten the locknut.
  4.  
  5. Have the alignment checked at a reputable repair facility.
  6.  

 
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