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Youdoitstore, Garage Door Repair, Perrysburg, OH


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You are here: Home > Garage Door Repair Instructions > Torsion - Replace Torsion 2 Spring Door

How to replace a broken torsion spring on a two spring door
 

 

If your door has two torsion springs, we recommend replacing both torsion springs at the same time.  Springs are rated in cycles, one up and one down equals one cycle.  When one spring breaks  the other spring is also reaching the end of it's cycle life. Also, while your door is in a state of disassembly, it's an ideal time to replace your cables if necessary.  Please see our cable replacement instructions for this repair.

CAUTION: Repairing a garage door is a dangerous task. Garage door springs are under extreme tension and require appropriate safety precautions. Realize and understand the risks before undertaking any repair. Your health and safety is the #1 concern. No amount of financial savings is worth jeopardizing your health. Failure to understand/follow the recommendations below could result in property damage, personal injury or death. While all efforts are made to provide accurate information and guidance, it is impossible to predict all repair circumstances. Accordingly, the user agrees that use of this website; products and information contained herein are at your own risk. In no event shall youdoit Door Repair be liable for any property damage, personal injury/death, or any other loss or damage that may result from your use of the information and products provided on this site. All information contained within this site is provided “as-is” without warranty expressed or implied. User assumes all responsibility/risk for use of information and products purchased.

Cables, track, rollers, door sections and all other components of your garage door system contain many sharp edges, burrs and pinch points. It is essential that you wear gloves, preferably leather, as you are inspecting and servicing your garage door.

Do not attempt any garage door related repair unless:

1) You utilize the proper tools and safety equipment. Safety glasses and gloves must be worn at all times. Work boots are recommended. Loose fitting clothing and jewelry should NOT be worn during any repair.

2) You must possess a reasonable amount of mechanical aptitude and experience.

3) You are physically able to complete the task (climbing ladders, using wrenches and installing springs require a reasonable amount of physical strength, agility and ability).

4) You are able to completely read, precisely follow/understand the instructions.

If you have any doubts about your ability to perform the work safely, we recommend you contact a door professional to complete your repair.
 
 
TOOLS NEEDED:

  • Sockets & Ratchet 3/8" - 7/16" - 1/2" - 9/16"
  • Ladder
  • Locking Pliers
  • C Clamps
  • Winding Bars
  • File
  • Gloves
  • Safety Glasses
 

Step 1
First, unplug garage door opener then disconnet garage door opener from garage door.
 

 
Step 2
Lock the door and place a clamp on the track above any roller.

 


Step 3
Unwinding an existing torsion spring.

If your door has two springs and only one spring is broken, you will have to unwind the second unbroken torsion spring. Count and mark down the amount of 1/4 turns removed to unwind the spring. When winding the spring, return the same amount of 1/4 turns to the new spring.

Position your ladder in a manner that your upper body will be off to one side of the winding cone.

Using a proper winding bar, insert the winding bar into the winding cone.  Insure that the winding bar is inserted the full depth of the winding cone.  We have wrapped tape on this winding bar to indicate proper insertion depth. 


Holding the winding bar with a firm grip, loosen the set screws. When the set screws are loosened the winding bar will move towards the garage door. In fact you can rest the winding bar against the door.

Next, insert the second winding bar into the next opening of the winding cone. Lift the winding bar slightly and remove the first winding bar. Continue to unwind the spring until all of the tension has been removed.  Please make note of the 1/4 turns removed from the unbroken spring.



Step 4

Removing the cables and cable drums.
Place your ladder to either side of the cable drums and loosen the set screws on the cable drum.

Remove cable from the drum and slide the cable drum away from the head plate.
 
Repeat the process on the second cable drum.

It may be necessary to file the shaft slightly for ease of removal / installation.
 
 

Step 5
Remove broken torsion spring.

Place your ladder in the center of the door where the spring is connected to the center bearing plate. Unbolt the springs from the plate.

Move your ladder to the side of the door with the broken torsion spring. Slide the shaft out of the head plate.

Remove the cable drum from the shaft.
Slide the broken spring down the shaft and remove from shaft.
Slide the shaft back into the head plate bearing to support the shaft.
Repeat this same process to remove the other spring.
 

Step 6
Wearing gloves, inspect entire cable. Replace if needed.
 


Step 7
Slide new torsion spring onto the shaft.
 
Place the cable drum back onto the shaft.
 
Slide the shaft back into the head plate bearing. Repeat this process for the other spring.
Do not tighten any screws at this time.

Place ladder in the center of the door and bolt the springs to center bearing plate.

Step 8
Setting the cables. Starting with the cable drum to your left, facing the door, insert cable into slot on the cable drum. Use care so that the cable is properly set into the cable drum.

Correct                     Incorrect
 
Slide the cable drum over to the bearing plate and turn drum in a counter clockwise direction until the cable is tight.
Insure that the cable is in the first groove of the cable drum.
Now tighten the set screws.  Use caution and do not over tighten.

While holding the cable tight, position a pair of locking pliers on the shaft against the header. This cable drum is now set.

Move to the opposite side of the door. Insert cable into cable drum.
Take care to insure that the cable is properly positioned in the cable drum and that it is following the first groove in the cable drum.

Slide cable drum over to the bearing plate.

Turn cable drum in a clockwise direction until the cable is tight. Tighten set screws.  Use caution not to over tighten.



Step 9
Winding the spring.

Position your ladder in a manner that your body is not in direct line with the winding cone and you  are comfortable. Insert winding bar into the opening in the winding cone.

Insure that the winding bar is inserted the full depth of the winding cone. We have wrapped tape on this winding bar to indicate proper insertion depth.


The chart below can be used to determine the proper amount of turns to apply to your torsion spring. A turn is defined as one complete revolution of the torsion spring on the door shaft. Tension is applied in quarter turns, It takes four quarter turns to apply one complete turn to your spring. You will need to measure the Cable Drum circumference and door height before referring to the chart below.

Circumference of your drum can be determined by wrapping a small length of string
around the cable drum, on the flat portion of the cable drum, and then measuring the amount of string it takes to go completely around the circumference of the cable drum.

Door height, s
imply measure the height of your garage door. Measure from the inside, as the door can overlap the opening.

Now find the circumference of your cable drum on the chart and match it to your door height. This will be the total amount of turns you will need to apply to your torsion spring.

This chart represents the proper amount of turns needed to open your garage door properly.
You may need to add ¼ or ½ turn of tension to get your door to balance properly. Over time garage doors will gain weight due to moisture, paint and other factors. This is the reason additional tension may be needed. Refer to our directions as to adding or removing spring tension.

Spring Turn Chart


Lift winding bar up towards the ceiling until the next opening in the winding cone is in position to accept the second winding bar.  Increase or decrease spring tension by no more than 1/4 turn at a time. Insert the second winding bar into the winding cone opening.

Remove first winding bar. Lift second winding bar towards the ceiling. repeat this process until you have achieved the correct amount of total turns.  You must not over wind torsion springs.

Test grip of set screws.  Before removing the final winding bar from the winding cone. Pull down slightly on the winding bar to ensure that the set screws are holding the winding cone to the shaft. If the winding cone turns on the shaft, tighten set screws further before removing ther final winding bar. When you have determined that the winding cone is firmly set, remove the winding bar.

Remove the locking pliers from the door shaft.

Repeat process on second spring.

 

Step 10
Testing the door. With your foot firmly on the garage door, remove clamp from track and unlock door.

Firmly holding onto the lift handle, slowly raise the garage door.  Be mindful of the balance of the garage door as you rasie it. Does it seem heavy? Does it seem to be opening to fast?

Open garage door fully.  Does the door clear the opening? Close the door, does it stay on the floor? All of these issues can be addressed by adding or subtracting spring tension. As little as 1/4 turn of spring tension can effect a garage doors balance.

If spring adjustment is required, you must clamp the shaft on a single spring door.

Reduce spring tension if the door is hard to pull down and won't stay on the floor.
Increase spring tension if the door is hard to open and won't stay fully open.

Only increase or decrease spring tension by no more than 1/4 turn at any time.



Step 11
Re-attach garage door opener and then plug the garage door opener into a grounded outlet. Test system.

 









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