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Removed the factory rear sway bar (26mm?) and replaced with Hellwig 7878 sway bar (1 1/4"). Disconnected shocks from lower mounts. Brushed down, cleaned and POR15'd the lower shock mounts, didnt realize until later that the U bolt holes need to be drilled out for the larger diameter Hellwig U bolt. Used 9/16\" bit. Old sway bar removed Comparison of the two bars Used a C clamp to seat the steel bushings inside the urethane bushings. The urethane bushings only required the supplied grease to push them into the end links by hand. Lower shock mounts drilled out and back on axle Finished install, used the middle hole for now. Had to run the male end link halves almost completely into the female halves in order to have sway bar arms level with the ground (X/C springs from ATS)
I installed the same Hellwig rear sway bar last year on my 2002 Ex and recently found that the hardware that was used on the passenger side end link snapped off and was just sitting there no longer engaged. I replaced with 3" long 1/2" x 13 grade 8 bolts with Nylock nuts. I will watch how they perform over the next few month to make sure they stay together as planned.
I installed the same Hellwig rear sway bar last year on my 2002 Ex and recently found that the hardware that was used on the passenger side end link snapped off and was just sitting there no longer engaged. I replaced with 3" long 1/2" x 13 grade 8 bolts with Nylock nuts. I will watch how they perform over the next few month to make sure they stay together as planned.
That's why I replaced what I could with grade 8 bolts and new metal locknuts from my local hardware store. Using the Hellwig u-bolts though.
Hey if you don't mind me asking, do you have a lift on your truck? I just bought a Hellwig 7640 and 7878 from a local guy for 150$!
My Ex doesn't have a lift and i didn't now if you were stock and the end-links worked. It looks like in your pictures that the end-links might be all the way together, thought you might be riding stock.
Last edited by tte531; Jul 15, 2019 at 04:16 PM.
Reason: Cant spell....
Hey if you don't mind me asking, do you have a lift on your truck? I just bought a Hellwig 7640 and 7878 from a local guy for 150$!
My Ex doesn't have a lift and i didn't now if you were stock and the end-links worked. It looks like in your pictures that the end-links might be all the way together, thought you might be riding stock.
The only suspension lift I have is from the installation of ATS X/C springs, maybe 3.5".
.... Finished install, used the middle hole for now. ...
I would go ahead and move to the rear hole (stiffest), you're not getting the full usefulness from the bar.
If you like the improvement from the rear bar, the front bar is a nice improvement, too.
