hellwig install issue (maybe)
Lead Driver
Joined: Oct 2010
Posts: 5,420
Likes: 16
From: Ouray, CO
To the OP:
When I did mine 3 weeks ago, I found the driver's side e-brake
backet was *NOT* in the hole that the sway bar link used.
In fact, the e-brake bracket was egg shaped and the bolt won't fit.
There was a round hole nearby which clearly was for the sway bar.
There were similars hole on both sides (1 for the e-brake, 1 for sway bar).
On the pass side, the e-brake hole I left alone.
Maybe you didn't use the "same" hole on both sides of the frame?
That would sure cause the sway bar to shift since 1 hole was lower
and farther away from the rear axle.
Maybe on the '02 the holes are different under there?
When I did mine 3 weeks ago, I found the driver's side e-brake
backet was *NOT* in the hole that the sway bar link used.
In fact, the e-brake bracket was egg shaped and the bolt won't fit.
There was a round hole nearby which clearly was for the sway bar.
There were similars hole on both sides (1 for the e-brake, 1 for sway bar).
On the pass side, the e-brake hole I left alone.
Maybe you didn't use the "same" hole on both sides of the frame?
That would sure cause the sway bar to shift since 1 hole was lower
and farther away from the rear axle.
Maybe on the '02 the holes are different under there?
Thread Starter
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Senior User
Joined: Mar 2011
Posts: 224
Likes: 0
maybe thats the problem to a point. I looked under the X tonight and saw we used the foward most hole. I do remember one hole being sightly egg shaped but didnt think to much about since putting the washers on. I guess it could have slightly moved foward causing the bar to shift. Both sides are in the same hole though. There are 3 holes as you said. from back to front the hole in the rear is higher, then there are 2 holes that are lower in front of that. I went with the most foward hole on both sides. Should I have gone with the middle hole? If I would have, the links dont look straight. If I used the rear hole then the bar would sit more level but the links wouldnt be straight at all. What holes did everyone use.
Logistics Pro
Joined: Jan 2011
Posts: 4,880
Likes: 3,395
From: Ohio
I put mine in the highest hole available. I thought the bar should be as close to level with the frame as possible. For all I know, I did it wrong. 
This is the driver's side with the brake cable.
This is the passenger side showing all 3 holes.
Also the passenger side showing the overall angle of the bar.
Hopefully these will help. Was hard to get a good picture in the dark and only half my fat gut under the truck.
This is the driver's side with the brake cable.
This is the passenger side showing all 3 holes.
Also the passenger side showing the overall angle of the bar.
Hopefully these will help. Was hard to get a good picture in the dark and only half my fat gut under the truck.
Cargo Master
Joined: Jul 2009
Posts: 2,885
Likes: 24
From: Chino, California
I actually removed the bolt holding the E-brake cable on the driver's side. I hooked it through the bolt for the top of the link. There was this flying V shaped back of that bolt which I had to hack saw off the bolt to remove it because it my steel brake lines won't allow me to pull it out with the length of the bolt.
I wonder what would happen if I drill out 2 new holes (one on each side) into the frame to bolt the links onto so it would be straight. Then we can cut that long metal sleeve a bit so the link look perpendicular to the bar. Has anyone tried that who may want to give us some insight? I don't think it would compromise the structure, could it?
Here is a photo of that flying V. I used the hole on the far left (rear) because that was the only hole big enough.
I wonder what would happen if I drill out 2 new holes (one on each side) into the frame to bolt the links onto so it would be straight. Then we can cut that long metal sleeve a bit so the link look perpendicular to the bar. Has anyone tried that who may want to give us some insight? I don't think it would compromise the structure, could it?
Here is a photo of that flying V. I used the hole on the far left (rear) because that was the only hole big enough.
Cargo Master
Joined: Jul 2009
Posts: 2,885
Likes: 24
From: Chino, California
I got a few shots of my Hellwig tonight. Notice the clearance I have between the hump on the bar and my diff. Ignore the pinion seal leak. I'll address that some other time.
Also, I took a pic of my link on the driver's side. I hooked the bracket on the bolt of the link and used the hole where the old e-brake bracket bolt went into for the "stabilizer" piece. This way, no obstruction.
Hope this helps.
Also, I took a pic of my link on the driver's side. I hooked the bracket on the bolt of the link and used the hole where the old e-brake bracket bolt went into for the "stabilizer" piece. This way, no obstruction.
Hope this helps.
Thread Starter
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Senior User
Joined: Mar 2011
Posts: 224
Likes: 0
It looks like both of you guys used the upper rear hole to place the end link in. How close is you bar to level and how close are you to the sensor? Do you have any issues with it not be centered off the rear.(sliding one way or the other) The thing I dont like is the angle of those links. I agree the drilling 2 holes higher and more forward might be a good idea. I like this bar but think they should have made a 2wd specific bar and not a universal excursion bar. I am still waiting to here back from the engineer at Hellwig. Cant wait to hear waht he has to say now. I will keep you posted when I find something out.
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Post Fiend
Joined: Oct 2002
Posts: 11,314
Likes: 4
Wow, that does look like some extreme angles on that vertical piece....
IIRC, mine had 2 pieces of flat 4 inch bar with holes spaced about 1/2" apart and you joined them such that you could make the length what you needed...
While the solid bar in your pic should be stronger, it doesn't give you any adjustments for length.... certainly would go back to the company to correct...
the forward facing legs of the bar itself should be as level as possible.
IIRC, mine had 2 pieces of flat 4 inch bar with holes spaced about 1/2" apart and you joined them such that you could make the length what you needed...
While the solid bar in your pic should be stronger, it doesn't give you any adjustments for length.... certainly would go back to the company to correct...
the forward facing legs of the bar itself should be as level as possible.
Lead Driver
Joined: Oct 2010
Posts: 5,420
Likes: 16
From: Ouray, CO
My install looks similar to both sets of pictures,
I have the same angle between the end link and sway bar too.
I suspect, the Ex has settled in the rear and that is adding to
the odd angle between the end link/sway bar.
If the Ex was 1-2 inches higher I suspect that angle would be better.
I'm hoping to add 1 or 2 inches of height and I'll see how that helps.
I have the same angle between the end link and sway bar too.
I suspect, the Ex has settled in the rear and that is adding to
the odd angle between the end link/sway bar.
If the Ex was 1-2 inches higher I suspect that angle would be better.
I'm hoping to add 1 or 2 inches of height and I'll see how that helps.
Thread Starter
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Senior User
Joined: Mar 2011
Posts: 224
Likes: 0
I have air bags as well. When I have 40lbs or so in them it raises the rear end about 2" or so. It does help a little but not like it should be. I think the bolt together bars are the old style links and the ones pictured are the new ones.
Cargo Master
Joined: Jul 2009
Posts: 2,885
Likes: 24
From: Chino, California
Yes, that hole we used was the only hole big enough for the bolt to go through, unfortunately. Due to the lack of good instructions from Hellwig, this was the only one we could use through the process of elimination. No drilling was required as they advertised. The bar does point downward towards the front. There is a lot of clearance from the VSS.
Last edited by jh818; Jun 7, 2011 at 08:47 AM. Reason: Grammar
Thread Starter
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Senior User
Joined: Mar 2011
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I also have a lot of room between the sensor right now. However if you were to level your bar out to where it should be and look back at the senor you would probably see it seems to close for comfort.
Thread Starter
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Senior User
Joined: Mar 2011
Posts: 224
Likes: 0
Well Hellwig called me and sent me an email. They think I should try the super duty kit. It mounts to the rear and not the shock mounts. This way it can be adjusted so the arms are level and not pivot at the shock mounts as they do now. I guess as long as the arms are long the right lenghth and the hoop is at the right angle this may be a solution. It appears the links are off set also. I believe this Part # is 7677. I will keep you posted if I end up using this. I am waiting for a call or email but I think they are sending one out for me to try.
Thread Starter
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Senior User
Joined: Mar 2011
Posts: 224
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UPDATE:
Hellwig emailed me back asking for clearance locations for the super duty bar. I think there will be an issue with the passenger side shock mount plate. This will not allow the super duty mounts to bolt on correctly.
Solution:
Hellig asked me to make the bar level and let him know what measurments I have. This includes the link length and also a safe distance from the sensor. Once I have the measurements they will make a custom make a bar for my application. He will be rotating the hoop (center of the bar) foward and making custom links.This may be a start to a new 2wd bar that is specifically for our application. I hope to get the measurments tonight and let hellwig know them tomorrow. I will keep everyone posted on the outcome and measurements I have. Thats great customer service if you ask me. Once I confirm everything fits I will let you know who to talk to. He is a great guy to deal with and I hope he helps you too.He did say it wont hurt anything to leave it the way it is, other than ground clearance. Wish me luck
Hellwig emailed me back asking for clearance locations for the super duty bar. I think there will be an issue with the passenger side shock mount plate. This will not allow the super duty mounts to bolt on correctly.
Solution:
Hellig asked me to make the bar level and let him know what measurments I have. This includes the link length and also a safe distance from the sensor. Once I have the measurements they will make a custom make a bar for my application. He will be rotating the hoop (center of the bar) foward and making custom links.This may be a start to a new 2wd bar that is specifically for our application. I hope to get the measurments tonight and let hellwig know them tomorrow. I will keep everyone posted on the outcome and measurements I have. Thats great customer service if you ask me. Once I confirm everything fits I will let you know who to talk to. He is a great guy to deal with and I hope he helps you too.He did say it wont hurt anything to leave it the way it is, other than ground clearance. Wish me luck