Hellwig Sway Bar 6908 - Manual (Page 3)

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4. Place the saddle brackets onto the U-Bolts on the axle tubes. Place the U-Plates over the D shaped
bushings on the bar and attach the bar to the U-Bolts and saddle brackets with the flat washers and
nuts provided.
LEAVE LOOSE AT THIS TIME to allow for adjustment later. See PHOTO 3.
6. Position sway bar on axle so that it clears all frame mounted components including fuel tanks, brake
lines, fuel lines, etc. Sway bar can be rotated back and forth on axle to maximize clearance.
7. Assemble end links by inserting hourglass bushings and then inner sleeves into end link loops.
Fully lubricate bushings and sleeves before installation.
8. Attach end links to the center hole of the sway bar as shown in photo 4 using a 7/16-20 X 2-3/4”
bolt and washers. Align end links for best fit as shown in PHOTO 4.
IMPORTANT NOTE –
Center hole position is only for determining hole location. The end link must be moved to the
outer hole prior to initial use.
9. The end links should be located as shown in PHOTO 4 and 5 so that the arms of the sway bar are
even with the bottom of the subframe. When satisfied with location of sway bar and end links, mark
hole location for end links on subframe.
10. Prepare to jack up vehicle by placing wheel chocks on the front wheels. After the rear of the vehi-
cle has been raised,
support frame on jack stands and remove rear wheels. Make sure end link
hole location has been marked before raising vehicle as hole location must be determined with
the full weight of the vehicle on the suspension.
11. Transfer hole location to outer edge of subframe rail. A piece of card board can be used by marking
the location of the hole on the cardboard and transferring the location to the outer rail. Drawing a
line on the subframe square to the subframe rails will keep the hole location square. See PHOTO
6,7,&8.
12.
Review end link mounting detail before drilling holes. BEFORE DRILLING ANY HOLES IN
THE RAIL—RELOCATE AND PROTECT ANY FUEL OR BRAKE LINES THAT MAY
INTERFERE WITH THE DRILL BIT OR SWAY BAR INSTALLATION.
13. Drill a 15/32 (.468) hole through
BOTH walls of the subframe. Make sure holes are square to one
another when drilling holes. It is easiest to drill through the outer wall first and use a transfer punch
to mark location on inner wall of subframe.
14. Drill an 11/16 (.688) hole through
OUTER wall of subframe ONLY. See photo 7. A step drill
works wellfor this application. Do not use a hole saw as the hole must be a close fit to the spacer
tube.
559-734-7451 800-367-5480 FAX 559-734-7460
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Remove undercoating where
large washer contacts frame.
Mark hole location and trans-
fer to outer rail..
6908 (R-6908) 04/17/07