Hellwig Sway Bar 7653 - Manual

INSTALLATION INSTRUCTIONS
FRONT STABILIZER BAR
(00-04) 6.1 & 8.1 SUBRUBAN, AVALANCHE
(2500-3500) 2 & 4 WHL DR
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION
7654 ( R-7654 ) 07/08/04
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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 TIRES.
NOTE: TO EASE INSTALLATION AND TO PROPERLY ADJUST BAR, THE WEIGHT OF THE VEHICLE MUST BE ON THE
SUSPENSION, AS IF DRIVING DOWN THE ROAD . DO NOT RAISE VEHICLE BY FRAME.
NOTE: THIS UNIT IS DESIGNED TO REPLACE THE FACTORY INSALLED FRONT SWAY BAR USING THE FACTORY U-PLATE
MOUNTING BOLTS .
1. Remove the factory installed front skid plate.
( Remember this procedure, you will have to reinstall the front skid plate later).
2. Install the U-plates to the factory sway bar frame mounts that are welded to the frame. Start the self tapping bolts closest to the bumper first.
Leave
loose at this time. These U-plates will have to be rotated out of the way to allow for clearance when installing the sway bar. See photos one (1)
and two (2).
3. Install the end links on the lower control arms. TIGHTEN SLIGHTLY JUST UNTIL BUSHING START TO BULGE.
See photo three (3) and the
line drawing. DO NOT OVER TIGHTEN.
4. Install the D-shaped poly bushings on the sway bar in approximately the same location so that the bushings line up with the U-plates on the frame.
SEE PHOTO ONE (1).
5. Raise the sway bar up into position onto the end links and rotate the U-plates around the D-shaped poly bushings so the U-plates are supporting the
sway bar.
6. Start the remaining self tapping bolts on the other end of the U-plates.
Leave loose at this time to allow for adjustment. See photo one (1).
7. By moving the sway bar to the right or to the left. The end links can be aligned in as near up and down as possible.
8. Tighten all the self tapping bolts on the U-plates to the factory specifications.
9. Reinstall the factory installed front skid plate that you removed in
step one (1). Torque to factory specifications.
10. Bounce the vehicle and check for clearance on all the undercarriage components. Turn the front wheels full lock left and then to the right making
sure that you have a minimum of
( 1 inch) of clearance is maintained between the tie rod and the swat bar. Be sure that all nuts and bolts securely
tightened. Check and see that all wires, fuel and brake lines etc. are all clear of this installation and cannot be damaged. Recheck your installation
after one (1) week of driving and every thirty days thereafter.
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE
CARDS AND THE WARRANTY FORM
559-734-7451 800-367-5480 FAX 559-734-7460