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Old 06-29-2018, 12:35 PM
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commodor47 commodor47 is offline
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Join Date: Jul 2006
Location: Blandford, MA
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This post was copied from It is a great explanation of how to move the shells up (or possibly down) on the torsion bar.

At one point, the bottom of our upper entry door was rubbing on the top section of the lower door closest to the hinge. It was enough to wear the paint away leaving a shiny aluminum surface exposed. It was actually removing some of the metal. That is the way our TM was behaving when we purchased the unit from the first owner (we are the second owners) in 2004.

Sometime around 2006 the owner of MCD (TM dealer in West Yarmouth, MA) explained the process of raising the curb side of the outer shell to correct the door issue. He explained the adjustment available for the white rectangular lift arms. Near the base of the tube, where it receives the end of the torsion bar, is a slight bulge. The bulge is on both sides of the rectangular tube. You will note the bulge extends slightly above the top two bolts holding the torsion bar in place. Because the bulge ends at some point, it may not be possible to move/drive the rectangular tube down any further. However, there should be ample room to raise the rectangular tube up (away from the torsion bar end).

At our TrailBlazers Jubilee Rally in Niagara Falls in 2012, one of the factory reps came by and adjusted the height of the rectangular lift arms using the same process as MCD. He said over time the lift arms tend to slip down.

Dana at MCD said to use an upright 2x4 on top of a hydraulic jack, placing a spacer between the top of the 2x4 along the bottom of the shell for support. Place the support about half way between the rectangular tube and the end of the upper shell. Make sure to apply enough upward pressure to keep the 2x4 in place.

Before doing anything else, use some masking tape (or anything else that might do the same thing) and make alignment marks on the rectangular tube and the torsion bar such that you can return things back to their original position should the following adjustment fail to solve your issue.

Next loosen the 4 bolts holding the end of the torsion bar to the bottom of the rectangular tube.

Now add more upward force to the 2x4. At this point the outer shell will not move upward but you will have placed enough force for the next step.

Use a rubber mallet and strike the top portion of the curved torsion bar. It may take several strikes before the rectangular tube starts moving upward. Be careful as you strike the torsion bar as the mallet will tend to bounce and hit the side wall of the box causing small depressions (ask me how I know). Check your alignment marks for movement.

Repeat the process of increasing the upward force on the 2x4, striking downward on the top of the curved torsion bar.

It may take several strong strikes on the curved part of the torsion bar before you see any movement.

Keep an eye on the large black plate holding the torsion bar up against the bottom of the box. You don't want that plate pulling out.

This process may be what is needed to close the gap between the end of the upper shell and the lower shell (curb side) when the TM is opened. It should also help with a door alignment issue.

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Dick & Jeri in Western MA
2003 2720 SL
2007 Ford Explorer Sport Trac Limited 4x4 - V8
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