Hello,

I've got a quad cab 03 Dakota 4x4 manual transmission.

Replacing the upper and lower control arms. I have everything taken apart to the point that the torsion bars have no tension on them (bolt removed from torsion keys and lower control arm is hanging loosely). The keys are still on the bars as they are stuck too.

I cannot get these torsion bars out. Part of the issue is rustiness. However, I'm a bit lost on how these would come out with no rust. There's no opening behind the torsion keys to beat it from the back and if I beat it from the front it would go in to the same cross member blocking the back.

Seems maybe I need to pry the LCA at an angle where I can hit it forward? Or pry the back down and hammer forward?

Any advice on getting these torsion bars removed is greatly appreciated. I'm pretty close to picking up an angle grinder to chop the LCAs apart, but then I'm still not sure I'll get the new ones on. Where am I going wrong?

Thanks!

 

The bars "float" in the LCA and keys. It's just a friction placement to my knowledge. So rust is your primary enemy.

 

Thanks for the reply. Even if there was no rust holding these together, I'm confused how I'm supposed to get enough room to move the bar out of the LCA or key (forward or backward.

There's also a pin on the front of the LCA to stop the bar from shifting forward. Am I to remove this pin?
Replacement LCA came with the pin in place, leading me to believe I shouldn't need to remove it.

 

From the FSM:

REMOVAL

CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.

(1) Raise and support the vehicle with the front suspension hanging.

(2) Turn the adjustment bolt counterclockwise to release spring load (Fig. 14).

NOTE: Count and record the number of turns for installation reference.

(3) Remove the adjustment bolt from swivel.

(4) Remove torsion bar and anchor. Remove anchor from torsion bar.

(5) Remove all foreign material from torsion bar mounting in anchor and suspension arm.

(6) Inspect adjustment bolt, bearing and swivel for damage.


INSTALLATION

(1) Insert torsion bar ends into anchor and suspension arm.

(2) Position anchor and bearing in frame crossmember. Install adjustment bolt through bearing, anchor and into the swivel.

(3) Turn adjustment bolt clockwise the recorded amount of turns.

(4) Lower vehicle and adjust the front suspension height.

 

I recommend you go get a can of Fluid Film and soak the areas that are rusted. I dont understand how but it works well to break the rust bond.

My experience and eye opener was on the ram when I had to repack the front bearings. The caliper bolts were undisturbed for so long they were stuck. short breaker bar would not crack it, long breaker bar would not crack it, long breaker bar with extension would not crack it. No room for an impact driver. Frustrated I sprayed them at the contact point (bolt shoulder to caliper) with the fluid film, went inside and started watching youtube vids on breaking bolts free. Went out an hour or so later and with the long breaker bar the bolts broke free pretty easily. Figuring I'd have the same problem on the other side I sprayed them to allow them to soak while I worked on the 1st side, those broke free with little effort using the long bar.

looking at your 2nd pic with the key, I'd soak it and load it back up under tension, then release it

 

I'm struggling with this right now; were you ever able to get them out? What ended up working for you if so?

[QUOTE=Akleiman;3565939]Hello,

I've got a quad cab 03 Dakota 4x4 manual transmission.

Replacing the upper and lower control arms. I have everything taken apart to the point that the torsion bars have no tension on them (bolt removed from torsion keys and lower control arm is hanging loosely). The keys are still on the bars as they are stuck too.

I cannot get these torsion bars out. Part of the issue is rustiness. However, I'm a bit lost on how these would come out with no rust. There's no opening behind the torsion keys to beat it from the back and if I beat it from the front it would go in to the same cross member blocking the back.

Seems maybe I need to pry the LCA at an angle where I can hit it forward? Or pry the back down and hammer forward?

Any advice on getting these torsion bars removed is greatly appreciated. I'm pretty close to picking up an angle grinder to chop the LCAs apart, but then I'm still not sure I'll get the new ones on. Where am I going wrong?

Thanks!

/QUOTE]

 

Hey csusam - I did get them out in the end!

I got a great and very detailed description from this post:

https://dodgeforum.com/forum/1st-gen...ml#post3565362

Reference that post for the exact details of what to do.

You have to remove the cross member holding up transmission to be able to drop the torsion bar and control arm straight down - as far as I can tell, there is no reasonable alternative.. Once removed from the vehicle, I also had to slice my old lower control arms off the torsion bars with an angle grinder as they were so rusted on (this was pretty easy to do compared to other descriptions I've read on the same issue).

I hope that helps and good luck!

[QUOTE=csusam;3571125]I'm struggling with this right now; were you ever able to get them out? What ended up working for you if so?

 

Awesome, thank you! I'll likely be trying this out this weekend too.

[QUOTE=Akleiman;3571127]Hey csusam - I did get them out in the end!

I got a great and very detailed description from this post:

https://dodgeforum.com/forum/1st-gen...ml#post3565362

Reference that post for the exact details of what to do.

You have to remove the cross member holding up transmission to be able to drop the torsion bar and control arm straight down - as far as I can tell, there is no reasonable alternative.. Once removed from the vehicle, I also had to slice my old lower control arms off the torsion bars with an angle grinder as they were so rusted on (this was pretty easy to do compared to other descriptions I've read on the same issue).

I hope that helps and good luck!

 

Hello again! Thanks to your help I was able to get the old ones off. I've now got the new ones and having some trouble getting them to fit. Was this a bit of a pain and you just had to find the right position/maybe encourage them with a hammer, or did they go in easy for you?

[QUOTE=Akleiman;3571127]Hey csusam - I did get them out in the end!

I got a great and very detailed description from this post:

https://dodgeforum.com/forum/1st-gen...ml#post3565362

Reference that post for the exact details of what to do.

You have to remove the cross member holding up transmission to be able to drop the torsion bar and control arm straight down - as far as I can tell, there is no reasonable alternative.. Once removed from the vehicle, I also had to slice my old lower control arms off the torsion bars with an angle grinder as they were so rusted on (this was pretty easy to do compared to other descriptions I've read on the same issue).

I hope that helps and good luck!

 

It went together pretty easily for me. I did take a metal brush to the torsion bars to knock off the rust. The bars should hold to the LCA with tension only based on my understanding.