Hellwig Sway Bar 7648 - Manual

INSTALLATION INSTRUCTIONS
REAR STABILZER BAR
95-01 EXPLORER, EXPLORER SPORT, SPORT TRAK
95-01 MAZDA NAVAJO
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION
7648 ( R7648) 06/09/04
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 SUSPEN-
SION, AS IF DRIVING DOWN THE ROAD. DO NOT RAISE VEHICLE BY FRAME.
NOTE: THIS UNIT IS DESIGNED TO REPLACE THE FACTORY INSALLED REAR SWAY BAR USING THE FACTORY END LINK
HANGER AND AXLE BRACKETS.
1. Remove the factory installed anti sway bar. Remove the mounting bolts on the rear axle mounting brackets. Leave the end
link hanger brackets attached to the frame as they will be reused in installing the new rear sway bar.
Do not discard the
mounting hardware it will have to be reused as well.
2. Install the D-shaped poly bushing on the new sway bar in the same location as the factory sway bar.
3. Install the U-plates over the D-bushing and install on the axle brackets using the mounting bolts that were removed in step
one ( 1 ).
Leave loose at this time to allow for adjustment later. SEE PHOTOS TWO & THREE.
4. Raise the arms of the sway bar up to the factory hanger brackets and attach with the mounting hardware that was removed in
step one ( 1 ).
5. Align the sway bar to be centered and so the end links are straight up and down as possible. SEE PHOTO ONE.
6. Torque all mounting hardware to the specified rate.
7. After one week of driving recheck your installation. Recheck on a monthly regular basis thereafter.
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET, ALL IMORTANT
NOTE CARDS AND THE WARRANTY FORM
DRIVERS
SIDE
PASSENGER
SIDE
1
2 3
559-734-7451 800-367-5480 FAX 559-734-7460