torsion bar limbo

[flameguitar]

I have been searching for days on the internet, at the library, the chevrolet dealer, salvage yards, and this website for a feasible solution to the curse of the faulty, rust inhibited torsion bar. I have a 1995 AWD with the old style 41" torsion bars, the passenger side bar broken. My current theory is that it may be possible to purchase both 36" torsion bars and the crossmember from a '97 AWD astro at the salvage yard in the hopes that the 36" torsion bars will fit the sockets of the control arms on my van, and the crossmember match the bolt holes at the frame and the transmission. I realize there is a upgrade kit at overlandvans.com but I have only $300 some odd dollars to spend. Merely replacing the bar with another 41" bar from a salvage yard would likely turn out to be a temporary solution as these torsion bars rust inside the torsion bar anchor adapter, a steel cylinder that unfortunately encases 6" of the torsion bar in a mix of sludge and moisture picked up from the road. I would sure like to think there is a more sensible solution for more Astro AWD owners out there, myself included; therefore, any help that would lead to a remedy to the torsion bar blues and not cost the price of what the van is worth would be greatly appreciated.

[disastro]

Better late than never? I replaced the bars on my '96 last summer(07). GM parts direct has the shorter bars & adjuster for $400+. I removed the crossmember to get the unbroken bar out. Then got the bar compresser on ebay.

[kristian80]

it is possible to change the whole system across, i did it in my 93 AWD with a small amount of modification to the bracket where the transfer case sits nothing a drill and grinder cannot fix.

[flameguitar]

This is author of the original post. Still driving the Astrovan, it's now May 31st, 2010. 250,000 miles and going.

What I did was order a torsion bar from a salvage yard in Oregon. It arrived from UPS with the anchor boot still attached and a portion of the cross member. I took it to a shop and had the parts separated with a press. The torsion bar end was partially rusted but was still usable. Sanded it down and painted it with rust-oleum.

The broken torsion bar on the van could not be separated by a press because both pieces were connected to the cross member. So I cut the torsion bar off with a grinder and slid the front end of the bar out. Then I worked for 8 hours with the grinder 4 inches from my face, wearing a pair of goggles and face cloth, grinding the remaining portion of the torsion bar off, so the porkchop could be slid through the crossmember.

[astroturf]

This is author of the original post. Still driving the Astrovan, it's now May 31st, 2010. 250,000 miles and going.

What I did was order a torsion bar from a salvage yard in Oregon. It arrived from UPS with the anchor boot still attached and a portion of the cross member. I took it to a shop and had the parts separated with a press. The torsion bar end was partially rusted but was still usable. Sanded it down and painted it with rust-oleum.

The broken torsion bar on the van could not be separated by a press because both pieces were connected to the cross member. So I cut the torsion bar off with a grinder and slid the front end of the bar out. Then I worked for 8 hours with the grinder 4 inches from my face, wearing a pair of goggles and face cloth, grinding the remaining portion of the torsion bar off, so the porkchop could be slid through the crossmember.

Good to hear you got it fixed. Jim

[Big_kid]

Thanks for the update. Stick around and post once in a while!