Can't believe there isn't one of these in the tech folder already.

Installed a Hellwig rear anti-sway bar on a 2002 E-350 van today & took some pics. I paid $180 on Amazon, shipped.

This is a simple install that took about 90 minutes with phone interruptions.





Tools -
19mm & 22mm sockets and wrenches + extensions
1/2" drill bit
A few other random things that are probably on your workbench right now, like a hammer, vice-grips etc.




Jacked it up & put it on stands at the axle to keep the suspension aligned.




I located the endlink mount points on the frame rail. I didn't have the correct hole pre-drilled so I enlarged an existing one that happened to be in the right spot. 1/2".

The frame is made of some hard steel, this took about 15 min.




Premount the bar to the axles. Left the nuts loose for repositioning. All bushings greased.




Bolted one endlink to frame & tightened (50#)




Attached bar to endlink, left nuts loose. Then attached other endlink to bar BEFORE mounting to frame (it doesn't work the other way).

From there I started snugging everything up sequentially while keeping the bar fairly parallel to the ground & the endlinks perpendicular and avoiding any preload on the bar.

Ubolts = 40#
frame bolts = 50#
endlink/bushing bolts = about 10#, just til they start to bulge a bit






End result, the endlinks hang about 1" lower than the shock mount but there's almost 2" of excess there. Hacksaw coming soon. I may tinker with alternate ways to mount everything first. As is they have 8" of clearance.

Driving impressions - did about 50 miles tonite, it's a dramatic difference in the overall driveability. Doesn't feel much like a van anymore, the top heavy-ness is gone. Exactly as expected.

 

Might want to consider putting a touch of zinc or other corrosion controller when you enlarge holes in the frame. The frame on these vans is made from A36 structural steel, and its not known for its corrosion resistance (though, as you have learned, its not easy to drill or bend, with a tensile strength of nearly 80,000 PSI).