TorqueMaster Cone and Spacer Replacement

TorqueMaster Cone and Spacer Replacement

In this tutorial, we will show you how to replace the cone and spacer on your TorqueMaster torsion springs. There may come a time when your door will not go up and down anymore. You go in to replace the springs on your door, only to discover that the only thing wrong with them is that the cone has broken or the spacer has cracked. This is actually a much cheaper fix than if the spring itself breaks, as you can just order a new cone or spacer as opposed to having to get a whole new spring.

This process is best completed with a vice, a hammer, a screwdriver, a pair of vice grips, pipe wrench, and a cloth for getting some of the grease off if the cone becomes difficult to turn. There are parts in this video that do not apply to simply replacing the cone or spacer, and are for shipping the springs internationally, which is not a concern of most people completing this tutorial.

Both the TorqueMaster I and TorqueMaster II systems work fine with this process of taking off the cones and replacing the spacers. Whether you have springs with round cones, as we show in this tutorial and the accompanying video, or springs with hexagonal cones, the process will be the same for getting them replaced.

TorqueMaster Cone and Spacer Replacement

1. First, if your spring has a plastic cover on it, remove it and put it aside.
2. Next, position the winding cone inside the vice so that the top of the wire of the spring is just back from the end of the vice.
3. Because the wire is close to the stop on the cone, it cannot be removed right away with just a pipe wrench. You need to take a screwdriver and a hammer to the wire on the end of the cone, until the spring has been moved away from the stop. This step doesn't always have to be done, and only comes up when there isn't a way to grip the end of the spring with a wrench.
4. Once you have the spring loose from the end, move the spring foward in the vice so that the cone and five to seven coils of the spring are sticking out past the end of the vice.
5. Next, place a pair of vice grips on the cone of the spring, while grabbing and hooking the spring from the opposite direction with the pipe wrench. If you have this hooked correctly on the spring, it will not take much effort to remove the cone. If you don't, you can hurt yourself and possibly break parts off of the spring.
6. Holding the pipe wrench stationary, turn the vice grip counterclockwise to unwind the cone from the spring. Be careful as you do this, as the cone with the vice grip attached will shoot out about six inches once it is loose enough because of the spacer inside of it.
7. If you are replacing just the cone, take the old cone off of the spacer and skip ahead to step 10.
8. If you are replacing the spacer, pull that out after you have pulled the cone off of it.
9. Grab the new spacer, or the old spacer if you aren't replacing this part, and push it back inside the spring. You should feel it hit the stationary cone, and it will be difficult to push it in any further. The spacer should stick out about six inches from the end of the spring.
10. Once the spacer is in place, grab the new cone and place it on the end of the spacer.
11. In order to get the new cone onto the spring, push on the end with the palm of your hand. You will feel a lot of resistence when you do this; this is to be expected. It is best to push with your left hand, and turn the winding cone back onto the spring with your right hand. Turn it as far as you can by hand, and then apply a vice grip to the winding cone to finish tightening it on.
12. The final step of the process is to put a new plastic shield over the spring, which helps to keep the spring quiet as it rolls around in the tube.

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