The spring plate and torsion bar are solid and it just wiggles as a whole unit. I have to knock the torsion bar through to get it off. I wonder if I can fit it to the torsion bar off the bus and then slide the whole lot back in? What do you reckon?
Hmm - one thing I would advise in case you ever want to go back, is to keep the inner spline/torsion bar in the exact position you found it. If you think you can do that, then it's got to be worth a go, but seriously, once you separate the two parts I would have thought inspection would show the problem.
Yes I see the damage there, but is this damage you've done or was it like that? I'm guessing you didn't pay much attention before it jammed - I wouldn't have. How about the end of the torsion bar, could it be slightly out of shape from a misplaced whack?
I think it is just on the spring plate. The torsion bar looks fine. I did try to file any burrs off and retry earlier but same again. Not sure what to do to rectify the situation really.
Try the old ones? If they slip on, send your plates back? Have you seen how splines are cut? Brute force (pressed) and a mulifaceted chisel for want of a better description! The tool must wear and must be pretty expensive to replace...
Id suggest that the damage may be a manufacturing fault, looking at how the scoring goes, something has spun to do that..I very much doubt PSG's torsion bar could do that. you could try dressing the spline with a very fine needle file and some patience - if there is a burr, you'd feel it before filing and gone when dressed..go carefully though
There are more delicate ways of doing it, but pretty sure I saw Transporterhaus using one of these and a press. Each set of teeth cuts a bit more out like a tapered tap.
Yep that's the tool Steve! There is a precision engineering company in Redditch that makes those and gears, they can also harden them up etc..we've used them before on various projects
@zed @MorkC68 I took the torsion bar out, managed to get the spring plate on, it was tight fitting like block of wood and hammer job, and now the problem is the inner bushing, the machining is way off. It is tight to slip on the spring plate to the point that it would expand in size slightly to slip on, thus making it not fit the torsion tube. Here is a pic of it sitting on the spring plate It sits about 1.5 to 2mm too small for the diameter it needs to slip over. So that's the problem. And with it being tapered outside, it wedges in. So originally, the splines were super tight, to the point I think maybe I shouldn't have banged it on, and now it's the bushing. So I guess I will need to source new ones. I will have to speak to coolair and tell them I had this issue, and hopefully there will be a rapid replacement. I have seen urethane bushings for ghia but not sure if they are in the uk. Any ideas?
Have you tried softening the rubber donut slightly (warmer environment) to make it more supple? Talcum powder someone recommended as a lubricant too, this may help with the above. From memory they need a bit of brute force to get them in, that's what gives them their performance if that makes sense
I greased it right up, and used the hammer and wood method but it just felt like it was bouncing off the jam point.
