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  1. #1

    Default Torsion bar removal problem

    Hello. I am new to this site and I have a question so I hope this is the right spot to ask. I have a 2002 2500HD chevy ex-cab with the 6.0 engine. I have the new torsion key leveling kit to put in it. I have the special tool needed to remove the tension from the bars. with the tension removed, I can not get the bars to slid out. The torsion bars seem to be rusted in. I have been soaking them in PB Blaster twice a day for a week and still no luck. I have pounded the heck out of it too. Any one have an idea what I can do to get the torsion bars out?

  2. #2


    Did you unload them all the way? Try removing one of the shock bolts. That will take all the tension off. Once the tension is off drive the bar forward with a drift and the key will fall out.

    2004 SILVERADO 2500HD LS
    Pro Comp Leveling Kit
    285-75-16 Cooper ST All Terrains
    Pro Comp Programmer
    Bilstein Shocks
    Linux Bed Liner
    Tinted Windows

    Other rides:

    1967 Landcruiser <350 Chevy>
    1970 Camaro
    1990 Geo Metro Convertible
    2007 FJ Cruiser

  3. #3
    Master Mechanic tattooed4life's Avatar
    Join Date
    Apr 2008
    Stevensville MI


    I soaked mine with PB Blaster for several weeks and they still wouldn't come out. I didn't want to pay a shop to do the work so I kept soaking them for almost 6 months, I tried almost every other week to get them out and they wouldn't budge. Finally broke down and took it to a truck repair shop on town. They got them out after 6 hours. The mechanic said it took a hydraulic press, heat and a big a$$ sledge to free them. I know now I couldn't have gotten them out on my own especially after my buddy took them his 04 and it took just over 4 hours to get his out. His is 5 years newer and they were already rusted in that bad. Good ol michigan winters will do that!!! Good luck with yours!
    1997 Chevy K3500
    4x4 X-Cab Dually
    454 Dual Exhaust

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