Hellwig Sway Bar 7868 - Manual (Page 3)

7
8 9
7. Lubricate the inside diameter of the D-Bushings and place them onto the straight area of the bar as shown in PHOTO 6. In-
stall U-plates on D-bushings.
8. On the underside of the frame towards the bumper, mark holes for U-Plates. The hole will be approximately 2.68” forward
of the center of the oval hole already in the frame. Use threaded plate as a guide for hole spacing. Check clearance of
threaded plate to inner frame before drilling holes.
9. Drill a 7/16” hole on both frame rails. See PHOTO 7.
10. Attach U-plates to frame rail with 3/8-16 X 1” studs and serrated flange nuts as shown in the diagram on Page 2. Leave
loose for adjustment later. See PHOTOS 8 & 9.
11.
Fully lubricate bushings before installation. Press hourglass bushing into end link loop. Install 7/16” nut on threaded sec-
tion of heim joint before assembling the two halves together as shown in PHOTO 10.
12. Attach end links to the center hole of the sway bar as shown in PHOTO 11 and change end link length so the three end link
holes are parallel to the ground.
IMPORTANT NOTE – Center hole position is only for determining hole location. The
end link will be moved to the outer hole prior to initial use .
13. Lubricate the inside of the hourglass bushing and slide it over the quick disconnect pin. Insert the linch pin to keep the end
link from sliding off. See PHOTO 12. It will make disconnecting the end link easier if this bushing is regularly lubricated.
14. Align sway bar and end links and tighten 3/8” mounting bolts to 25 ft-lb. The bar should be offset to the driver side as far as
the bushings allow to maximize clearance between the sway bar and the steering box/pitman arm.
15. Place collar clamps on sway bar inside of the D bushings on the bar to keep the sway bar aligned during use. Torque bolts
on collar clamps to 5-8 ft-lb..
559-734-7451 800-367-5480 FAX 559-734-7460
7868 (R-7868) 07/13/2011
10 11 12
Drilled
Hole
Existing
Hole
Front of Vehicle
3/8” Stud
2.68”