Hellwig Sway Bar 7608 - Manual (Page 3)

1. If equipped with a factory rear sway bar, remove the factory installed rear anti-sway bar and all of the
mounting hardware . Do not discard the U-plate mounting bolts as they will be needed to install the new
rear sway bar. Do not remove the frame bracket from the frame rail if equipped with a factory sway bar
as it will be used to mount the new end links.
2. Choose the D-bushing that fits the u-plate for your application.
Factory RSB:
Use the narrow, tall u-plate
Without Factory RSB: Use the short, wide u-plate and saddle bracket.
3. Install the D-shaped poly bushings on the sway bar
Factory RSB:
Use factory mounting location as shown in photo (2)
Without Factory RSB: Locate inboard of shock brackets as shown in photo (4)
Locate the u-bolts inboard of the shock brackets as shown in photo (4).
Be sure to install the U-bolts under any brake lines, wires or hoses on
the axle to avoid any possible damage. Install saddle brackets by inserting
legs of u-bolt through the holes in the saddle bracket.
4. Position the correct U-plate brackets over the D-bushings
Factory RSB:
Reuse mounting bolts
Without Factory RSB: Use 1/2” nuts and washers
5. Tighten the bolts/nuts just enough to support the sway bar on the axle. The hump of the sway bar will
be tilted slightly downward for clearance around the differential.
6. Assemble the adjustable end links as shown in the detailed diagram (3). The male threaded end will go
the top clevis bracket installed on the frame.
7. Attach clevis to frame rail
Factory RSB:
Use factory frame bracket as shown in photo (2). Do not use supplied clevis.
Without Factory RSB: Locate the exiting hole in the frame rail as shown in photo (4), this will be
the mounting point for the clevis. If there is not a hole, assemble end links
to clevis and mark the frame for the best possible location for the top clevis
bracket as in photo ( 4 ). You will require a
1/2” drill bit to drill the frame.
If your vehicle has pre-drilled holes on the frame, enlarge hole to 1/2”
diameter. Assemble clevis to frame using 1/2” nut, bolt and washer on
frame side and torque to specification.
8. Attach end links to frame clevis using 7/16X2-3/4” bolts, locknuts and washers.
9. Adjust the length of the end link so that the arms of the sway bar will be level with the ground. Loosely
attach the end links to the sway bar’s arms using the 7/16x2-3/4” bolts nuts and thick washers as shown
in photos (2) & (4).
10. With the sway bar properly centered on the axle and the end links straight as up and down as possible
torque the mounting bolts to the specified rate. Double nut axle u-bolts and tighten. Make sure that the
9/16” nut on the end links is tightened to lock in the adjustment.
11. Test drive your vehicle and re-check your installation. Re-adjust and tighten as required. After one week
of driving re-check your installation. Re-check on a monthly regular basis thereafter.
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION
SHEET, ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM
7608 ( R7608) 02/06/06
559-734-7451 800-367-5480 FAX 559-734-7460