Hellwig Sway Bar 7898 - Manual

INSTALLATION INSTRUCTIONS
Rear Stabilizer Bar
Dodge 2500 - 3500 pickup w/ 4-6” lift
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION
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 MOUNT TO THE REAR OF THE AXLE TUBES WITH THE ARMS OF THE BAR
TOWARD THE REAR OF THE VEHICLE. THE HUMP SHOULD TILT SLIGHTLY DOWNWARD.
NOTE: THIS KIT INCLUDES LOCK NUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER BEING STARTED
BY HAND.
1. As shown in photo one (1), place D-shaped poly-bushings onto straight areas of the bar on each side of center hump. After installing D-
bushings onto bar, place U-plates on D-bushings.
2. Place U-bolts on axle tubes next to casting as shown in photo two (2).
When installing U-bolts, be sure to put U-bolts under any
brake lines, wires or hoses on the axle to avoid any possible damage.
3.
Before installing saddle brackets, reposition passenger side brake line so that it will clear the saddle bracket Place saddle brackets
on axle by inserting legs of U-bolts into the holes in saddle brackets. Saddle brackets must be installed so that one leg of the saddle
bracket is located on the cast center section with the leg just inside the raised lip on the casting. See photo two (2)
4. Raise bar and place D-bushings on saddle brackets by inserting legs of U-bolts through holes in U-plates. Install flat washers and hex
nuts provided on U-bolts. Do not use locknuts provided in kit on axle U-bolts.
LEAVE LOOSE AT THIS TIME to allow for
adjustment later.
5. Locate existing spare tire crossmember on vehicle frame. Place square U-bolt over frame rail just behind crossmember with legs of U-
bolt pointing downward. See photo (1).
6. Insert legs of U-bolt into slotted holes of the hanger brackets. Install hanger brackets with clevis inboard of frame rail and toward front
of vehicle as shown in photo three (3). Attach using 1/2” lock nuts.
LEAVE LOOSE for adjustment later.
7. Attach clevis to end of sway bar with 1/2 x1-1/2” bolt, thick washer and locknut as shown in photo (3).. Torque to 50 ft-lb.
7895(R-7895) 02/17/09
559-734-7451 800-367-5480 FAX 559-734-7460
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