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I noticed a rattling noise in the rear end a couple of days ago. It seemed like it was getting worse pretty quick so I crawled under it today and discovered the Hellwig sway bar was loose. The bar was no longer parallel to the ground like it was when I installed it. The nuts on the u-bolt that holds the bracket to the axle tube were loose on all four threads. I took the u-bolt completely off the driver's side to get a closer look at it and discovered that the bolt had partially worn through the axle tube. The bolt itself was also rubbing against the tube but the tube seems to have taken the worst of it. See the pic below. What gets me is that each nut is doubled and the nuts themselves weren't loose. It was like the u-bolt stretched out and eventually worked its way loose.
So two things... check that your hellwig brackets are all nice and tight. Two, do I have to worry about this axle tube? Should I take it to a welder and have material added back to the tube? Or just leave it as-is? The shot is looking straight up from the ground under the driver's rear axle tube.
Sterling axle tubes are .258 thick, I wouldn't worry about it For normal usage. If you plan on jumping it then it may bend
But seriously, short of crashing or smacking a curb at speed you are not going to bent it.
Ok that's good to know. I do pretty heavy and I had a lot of weight on the rear axle on the way out to the east coast so it is something that still concerns me.
There is an Excursion at the Citrus Heights pick n pull if you want a new axle.
I now live on the east coast. :/
Originally Posted by Tylus
maybe when you re-install it, consider putting a tack weld on that u-bolt
was the u-bolt grade 8? sounds like inferior material or you had too much tension on the unit
Could be too much tension, but I didn't want it to come loose. That didn't exactly work out. I'm pretty sure the u-bolt is grade 8. I can't imagine a softer steel digging into the tube like that but it's whatever Hellwig sent me.
Could be too much tension, but I didn't want it to come loose. That didn't exactly work out. I'm pretty sure the u-bolt is grade 8. I can't imagine a softer steel digging into the tube like that but it's whatever Hellwig sent me.
When you reienstall it use a torque wrench. Ubolts seem tight but that is usually them "bending" into shape rather then tension on the threads.
I am always amazed at how past "tight" it takes to get a ubolt to torque spec.
I noticed a rattling noise in the rear end a couple of days ago. ... the Hellwig sway bar was loose. The bar was no longer parallel to the ground like it was when I installed it. The nuts on the u-bolt that holds the bracket to the axle tube were loose on all four threads. I took the u-bolt completely off the driver's side to get a closer look at it and discovered that the bolt had partially worn through the axle tube. The bolt itself was also rubbing against the tube but the tube seems to have taken the worst of it. See the pic below. What gets me is that each nut is doubled and the nuts themselves weren't loose. It was like the u-bolt stretched out and eventually worked its way loose. ...
You must have a 4x4.
The 2wd Hellwig rear anti-roll bar mounting plate held by the U-bolt around the axle has a large plate welded to the axle which will prevent the U-bolt from rotating.
Any anti-roll bar I've ever installed has had some sort of tab/plate/bracket welded to the axle housing that anchored the anti-roll bar mounts.
Since the Ex did not come with a rear bar it looks like there is no bracket to anchor the U-bolts to on a 4x4.
I wonder what the later year Excursions have for mounting the optional rear bar on a 4x4?
I would certainly look into having a bracket of some sort welded to the axle housing to keep the U-bolts from rotating.
You must have a 4x4.
The 2wd Hellwig rear anti-roll bar mounting plate held by the U-bolt around the axle has a large plate welded to the axle which will prevent the U-bolt from rotating.
Any anti-roll bar I've ever installed has had some sort of tab/plate/bracket welded to the axle housing that anchored the anti-roll bar mounts.
Since the Ex did not come with a rear bar it looks like there is no bracket to anchor the U-bolts to on a 4x4.
I wonder what the later year Excursions have for mounting the optional rear bar on a 4x4?
I would certainly look into having a bracket of some sort welded to the axle housing to keep the U-bolts from rotating.
The bracket that the bar attaches to is also where the shock mounts. It's not welded to the axle, but it does nest onto a round slug that is welded to the axle tube and is held onto that slug by the U bolt. The slug into the hole on the shock mount keeps the bracket properly aligned.
My 4X4 looks exactly like your RWD setup for the shock and Hellwig mounting.
The bracket that the bar attaches to is also where the shock mounts. It's not welded to the axle, but it does nest onto a round slug that is welded to the axle tube and is held onto that slug by the U bolt. The slug into the hole on the shock mount keeps the bracket properly aligned.
My 4X4 looks exactly like your RWD setup for the shock and Hellwig mounting.
Crawled under there again and saw the slug vs welding.
Since the slug keeps the bracket from rotating that's impressive the U-bolt working loose can move enough to wear a groove like that in the tube.
Seems like adding a lock washer and double-nuts won't help if the U-bolt stretches.
Is there a torque for the U-bolts?
I think I am going to go with standard traction bars. I just need to find a set that won’t break the bank since the truck is more of a toy then a daily driver.
I think I am going to go with standard traction bars. I just need to find a set that won’t break the bank since the truck is more of a toy then a daily driver.
"standard traction bars" as in the factory Excursion traction bars? What exactly are you looking to improve or correct with your plans?
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