Torsion bars Options

[worn]

What is the deciding factor on when to replace the torsion bars? Looking at the pics from the original post they dont look too bad. I didnt realize they were so critical of a component.

Torsion bars are a highly stressed spring where the outer heat treated layer is where the highest stress is concentrated. The center of a torsion bar does virtually nothing which is why you can have hollow torsion bars.

When the outer hardened layer is compromised by corrosion, scratches, or gouging it creates a very localized stress riser where cracking will begin. Eventually the crack will propagate through the bar and the bar will fail catastrophically.

This isn’t speculation. It is an engineering reality. Having a bar fail will ruin your day.
Typical failure:


The bars in the 1st picture are scrap.

Is that one of your bars?