[WoodButcher]

Don't cut anything. Disassemble.

 

[flakburt]

Don't cut anything. Disassemble.

It's stuck. The broke end is stuck in the key tube. The newer torsion bars are shorter and don't have that combo key plus tube. Just a new key with the shorter torsion bar for 95 up astro and safaris. The newer shorter ones work in the older ones.
I just don't know of any other way to get that tube key off than cutting it off with a grinder.

 

[WoodButcher]

And how do you remove the remainder? I was thinking if you have more to grab or beat on leverage would be helpful.

 

[M_a_t_t]

Don't cut anything. Disassemble.

94 Safari torsion bars

I bought my van with a broken drivers side torsion bar and that came out with no problem, the intact one not so much. If one breaks replace both. Jack and support the van on the frame behind the control arms and use penetrating oil where the bars connect to the control arms. Use the correct GM...

www.astrosafari.com

 

[Bikley]

It's stuck. The broke end is stuck in the key tube. The newer torsion bars are shorter and don't have that combo key plus tube. Just a new key with the shorter torsion bar for 95 up astro and safaris. The newer shorter ones work in the older ones.
I just don't know of any other way to get that tube key off than cutting it off with a grinder.

On the broken side count the turns and remove the bolt and the part it threads into and you'll be able to drive it out the backside with a big hammer.

The unbroken one is where it gets fun. You have to have the unloading tool to remove the bolt, and on mine I couldn't get the sleeve off so I had to cut the torsion bar forward of the cross member and drive it out the same way. It doesn't do any good to cut the sleeve, you have to cut the torsion bar.

I added a more detailed comment on the link Matt provided.

94 Safari torsion bars

I bought my van with a broken drivers side torsion bar and that came out with no problem, the intact one not so much. If one breaks replace both. Jack and support the van on the frame behind the control arms and use penetrating oil where the bars connect to the control arms. Use the correct GM...

www.astrosafari.com

 

[Bikley]

On a side note here. Don't put the jackstands under the control arms. The front end has to be hanging to unload the torsion bars.

 

[flakburt]

I ground the adapter tube off. Used a cheap electric grinder with no guard. That was to get it close to the key. When grinding. I know they say to disassemble but grinding it off worked for me.