Hellwig Sway Bar 7643 - Manual (Page 3)

1. Install the D-shaped polyurethane bushings on the straight areas of the bar close to the shoulders or cor-
ners of the sway bar. To avoid any possible bushing noise, apply a thin layer of grease to the inside of
the D-bushing.
2. Remove the factory U-bolts that hold the lower shock mounts to the axle. These will be replaced with
the new U-bolts which are provided. Position the 3-hole adapter plates onto the U-bolts so that they are
flat against the lower shock mount brackets. The third hole will be above the rear axle. See photos 5
and 6.
3. Position the U-plates over the D-shaped bushing that are installed on the sway bar. Position the U-plates
and bushings so they line up with the U-bolts that are installed on the shock mount brackets. The U-
plates will mount on the top hole of the 3-hole plate and the upper leg of the U-bolt. Use standard 1/2”
hex nuts on the U-bolts and 1/2” lock nuts on the upper bolt. See photos 5 and 6.
4. Lubricate the outside and then install the hourglass bushings with the 3/4” hole in the male side of the
end link. Then lubricate the outside and insert the sleeve with the 1/2” hole. Repeat for the female side
but using the hourglass bushings with the 5/8” hole and sleeve with the 7/16” holes. Fully assemble the
end link following Photo 4. Leave loose at this time.
5. Attach end links to frame rail in the factory hole with the female side up using the 7/16 hardware and
lock nuts. See Photo 3.
6. Swing the sway bar arms up so they are level with the ground, adjust the end link length so the sway bar
arms are parallel to the ground and attach to the last hole using the 1/2” hardware and lock nuts. See
Photo 2.
7. This bar has three holes for adjustment, we recommend starting on the furthest out, softest setting and
then moving the end link to a different holes to match your driving style once you are familiar with the
vehicle’s new handling characteristics. See Photo 7.
8. Center the bar between the frame rails and then torque all mounting hardware to the specified rate in-
cluding U-plate bolts, U-bolts, end link jam nuts and end link bolts. Double nut U-bolts.
9. Bounce the vehicle check for clearance on all undercarriage components ie: exhaust, shocks, differen-
tial, wires, brake and fuel lines.
10. Test drive the vehicle and recheck your installation . Adjust as needed. Recheck your installation after
one week of driving and on a monthly regular basis thereafter.
ATTENTION INSTALLER: BE SURE THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET, ALL
WARNING AND NOTE CARDS AND THE WARRANTY FORM.
559-734-7451 800-367-5480 FAX 559-734-7460
7643 ( R-7643 ) 03/22/2013