Hellwig Sway Bar 7635 User Manual

Page 2

Install the D-shaped poly bushings on the flat areas of the sway bar on each side of the center
hump. Align the D-bushings with the flat areas on the rear of the axle shock mount brackets.

Position the U-plates over the D-bushings on the sway bar so that the long ends of the U-plates are
pointing upwards. Slip the bent plates into the shock mounts so that the bends push the holes to-
wards the U-plates. Fasten with the mounting hardware provided ( do not tighten at this time ).
The threads of the bolts should face rearward to avoid any possible contact. SEE PHOTOS 4 & 5.

LEAVE LOOSE AT THIS TIME TO ALLOW FOR ADJUSTMENT LATER.

3. Assemble the end link assemblies and attach to the arms of the sway bar. Attach the other end of the end

link assemblies to the frame angle brackets. Take note that there is a left and a right hand side frame brack-
ets. The frame brackets will be forward of the sway bar when attached properly. Tighten the lock nuts just
until the bushings begin to bulge slightly. Do not over tighten over damage to the bushings will result.

4. Rotate the sway bar upward so that the angle brackets are on the outside of the frames and the holes are

above and below the frame. SEE PHOTOS 2 & 3. Attach the angle brackets to the frame with the square U-
bolts, washers and lock nuts that are provided. Leave loose at this time to allow for adjustment later. Be
sure to move any wires, brake or fuel hoses to avoid any damage. Trim off any excess U-bolt to avoid con-
tacting the vehicles leaf springs or keepers.

5. Center the sway bar so that the end links are straight up and down and as level as possible to the vehicles

frame. Torque all the mounting hardware to the specified rate.

6. Bounce the vehicle checking for clearance on all under carriage components, exhaust, shocks, wires, brake

and fuel lines. Test drive the vehicle recheck your installation readjust if necessary.

7. After one week of driving recheck your installation. Recheck on a regular monthly basis thereafter.

ATTENTION INSTALLER:

BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET,

ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM

TORQUE TABLE

BOLT SIZE: 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs.

SAFETY:

BEFORE STARTING YOUR INSTALLATION, BE SURE TO SET PARKING BRAKE AND

CHOCK THE TIRES.

NOTE:

THIS SWAY BAR IS TO BE MOUNTED ON THE REAR OF THE AXLE SHOCK MOUNT

BRACKETS WITH THE ARMS OF THE BAR TOWARDS THE FRONT OF THE VEHICLE.

NOTE:

THIS KIT INCLUDES LOCKNUTS WHICH REQUIRE TIGHTENING WITH A WRENCH

AFTER BEING STARTED BY HAND.

7635 ( R-7635)

06/08/04

559-734-7451 800-367-5480 FAX 559-734-7460