Hellwig Sway Bar 7694 - Manual (Page 4)

11. Drill a 15/32 (.468) hole through
BOTH walls of the frame. Make sure holes are square to one an-
other 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 frame.
12. Drill an 11/16 (.688) hole through
OUTER wall of frame ONLY. See photo 7. A step drill works
well for this application. Do not use a hole saw as the hole must be a close fit to the spacer tube.
13. Insert 7/16 X 6” bolt through driver’s side rail as shown in PHOTO 9 with head on inside of frame
rail . Insert 7/16 X 5” bolt in same manner through passenger side rail.
14. For severe duty it is recommended that the spacer tube be welded to the outer frame wall. If the
spacer is to be welded, review severe service end link detail for your frame rail and skip to line 17.
IMPORTANT—
If any welding is to be done, the installer must ensure that all haz-
ards (fuel, electrical, etc) are eliminated and that fuel tanks, fuel lines, brake lines,
wiring, etc. are not affected by the welding operation.
15. Insert spacer tube from outside of rail until it contacts inner wall of frame rail and check fit. The
spacer tube must be 1/32” (.030”) shorter than edge of large washer as shown in PHOTO 11.
Failure
to do this will result in insufficient preload and noise. Cut, file or grind end of spacer tube to
achieve proper length.
16. Remove bolt and spacer from inside of frame rail.
17. Attach end links to frame rail as shown in detail and PHOTOS 5&6. Note that a 3/4” spacer is used
on the driver side rail only.
18. Torque end link bolts to 40 ft-lb.
19. Torque axle U-bolts to 60 ft-lb.
20. Tighten jam nut on adjustable end links.
21.
Bounce the vehicle checking for clearance on all under carriage components: fuel tank, shocks,
exhaust, differential, brake and fuel lines, etc. Test drive the vehicle and recheck all clearances and
the installation alignment. Adjust as needed. Re-check your installation after one week of driving and
periodically on a regular basis.
559-734-7451 800-367-5480 FAX 559-734-7460
Passenger Side Shown
.688 Hole in
outer wall only
Spacer Tube
Bolt inserted from
inside of rail to
check spacer
10
Spacer tube must be
1/32” shorter than
edge of large washer.
7694 (R-7694) 08/22/2007
11
Step Drill for
hole in outer
wall of frame