Hellwig Sway Bar 5802 - Manual (Page 2)

559-734-7451 800-367-5480 FAX 559-734-7460
1. If equipped, remove factory sway bar.
2. Locate the pre-drilled holes in the subframe as shown in photo (2). Attach frame bracket
to subframe using factory hardware if equipped with factory sway bar. If pre-drilled
holes are not threaded, use a 3/8-16 tap to thread holes and attach bracket using 3/8 X 1”
bolts, washers and lockwashers. See photo (3) for attachment of frame bracket. Torque
bolts to 20 ft-lb.
3. If your vehicle does not have these holes see diagram above and photo (4) for assembly
of frame bracket and end link. FULLY MOUNT SWAY BAR BEFORE DRILLING
HOLES IN SUBFRAME FOR CORRECT ALIGNMENT OF SWAY BAR AND END
LINKS. Make sure all fuel and brake lines, brake hoses, and brake cables are protected
before drilling any holes in subframe.
4. Place a round bushing on each side of end link hole and slide assembly into frame
bracket. Attach end link to frame bracket using 3/8 x 2 1/2” bolt and locknut. See photo
(5) and diagram. Leave loose at this time at this time to allow for adjustment.
5. Lubricate the D-bushings and locate on sway bar as shown in photo (1).
6. Position D-bushings in hanger of end link as shown in diagram and photo (6). Insert u-
shaped bushing support into hanger and attach with 3/8 x 2 1/2” bolt, washer and nut.
5802 ( R-5802 ) 02/15/07
559-734-7451 800-367-5480 FAX 559-734-7460
3/8 x 3-1/4” bolt and locknut
through subframe re-
quires .468 dia clearance hole.
Fully mount sway bar to vehi-
cle to determine location of
hole. Torque to 25 ft-lb
1/2 x 1” bolt and locknut.
Torque to 50 ft-lb
3/8 x 2 1/2 bolt and locknut.
Torque to 25 ft-lb or until
bushings bulge slightly.
Round Bushings
3/8 x 2 1/2 bolt, lockwasher,
and nut. Tighten until hanger
contacts bushing support.
D-Bushing
Mount this bracket to frame
with 3/8 x 1” bolts if pre-drilled
holes exist in frame. If holes
not present, mount to u-
bracket with 1/2” bolt as
shown.
This bracket not required if pre-
drilled holes exist in frame.