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Torsion bar issue

Forest Ranger

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Hello, after replacing my lower control arms my passenger side torsion bar is now riding on the control arm instead of passing through the whole in the control arm. Everything measures the same on either side and the pad under the keys are both fairly new. Any ideas on what would cause this?

Thanks
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Uncle Gump

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Did you put the weight of the vehicle on the suspension before you tightened everything up?
 

dvdswan

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Something bent, bushing holes on the frame wallowed out, torsion over tightened on that side, torsion bar weak.

edit: and what @Uncle Gump said.
 

Forest Ranger

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Yes I tightened everything once it was on the ground. Everything lined up fine with the original arms. All the mounting holes are fine. I did loosen that bolt nearest to it and put a jack under it to try a and maybe move it up but nothing. The bars are clocked the same as they were before.
 

gw33gp

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Are you sure you have the camber cams set right?
 

Forest Ranger

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The camber cams are on the upper control arms and I didn't touch them this job.
 

rubydist

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Looks to me that the passenger side lca is not made right - it looks like that hole for the torsion bar to pass through is too low on the formed part.
 

Uncle Gump

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I just noticed this post was in the wrong forum... I moved it to the 4WD suspension forum.

Looking at the pictures again... it appears like you have the torsion bar pretty much cranked to the MAX.

I think I would back off the torsion bars a bit.... loosen up the lower control arms a little and bounce the suspension a bit and see if it ends up in a bit better spot. then tighten the control arm.

Where it's set in the above pictures it looks like you have no suspension drop left in the system. I know people do it to get lift for bigger tires... but it is really NOT the way you want to set up a functioning suspension.
 

Forest Ranger

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Rudy, I suspected it was made incorrectly as well based on measuring around the stamping. The arm is being warranty out.

Uncle, That was one of the first things I tried, thinking that the arm rotating up might change something and allow it to move into a better position but it did not. Yes my suspension is cracked a lot but with aftermarket uppers I currently have a good bit of down travel. If the lift were the issue it would be on both sides. I've heard a lot of negative info about lifting these trucks in this way. It's been a good setup for 3 years of off roading with no issues from cv boots or steering components. These arms were original to the truck, not being replaced because of my setup. Check out how stuck the bars were.
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Forest Ranger

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Update,
I swapped out the control arm for another and had the same issue. But I had my friend who recently replaced his control arms check his and the passenger side has the same issue. (His truck pictured) Different brand arms too! So I guess this is just and problem for these trucks. Oh and I forgot to mention when I took the pictures my truck was on jack stands so that's why it looked so crazy lifted. Last twist, the replacement didn't come with the castle nut or cotter pin (that I returned with the first one) so I still can't drive it yet.
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Thanks
 

Uncle Gump

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What are you running for UCA's?
 

Forest Ranger

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They are from a company called BTF fabrication. They make a lot of long travel stuff mostly.
Screenshot_20220522-123239.png
 

Uncle Gump

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Do you run stock length shocks with those arms?

I'm gonna have to look those up.
 

rubydist

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Those look sweet
 

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