I installed the hellwig rear sway bar about a year ago. after about a week i started getting a rubbing or binding sound when climbing curbs, etc. I never could find where it was rubbing, so 3 weeks ago I decided to loosen everything up and re-adjust but that only made the rubbing worse. so last week, i decided to try again but accidentally cross-threaded and ruined one of the u-bolts. So I pulled the bar and replaced the factory u-bolts. It actually drives better without it, I don't think I'm going to put it back on. The rear suspension was so stiff, the the rear end hopped bad on the rough roads.

I wish I had taken some pictures, but I never could make it look right. I believe the bar was rubbing on the passenger side of the diff housing. With the C's of the frame rail pointing the same direction, I could never get the bar to slide over to clear the diff housing like i wanted. the end links wouldn't allow it.

Also the bar acted like it needed to be shortened an inch or so in the front-back direction to make the endlinks square up better with the bar. I could've shortened the end links easily enough, but they were the least of my problem. The directions say the bar fits 2wd and 4wd, maybe their not that universal.

 

I'm almost wondering if you might have gotten the wrong bar or end links by mistake. Hellwig really makes a superior bar and fitment is one of their strengths. After tossing out the instructions or using them for dog excrement (which is about all they're good for) the easiest thing to do is pre assemble all of the components and adjust and level and generally play until youre satisfied (check clearances etc.). 2 sets of hands is nearly a must although they neglect to mention that. A good synthetic grease is a must on all the bushings as suggested in the moron written instructions, eases installation and prolongs bushing life. Torque wrench is a must particularly at the axle u bolts.

Properly installed, the bar actually acts to limit wheel hop although that's not a stated benefit. It all but eliminates lean and bed roll and, at least in my case with an SD, enhanced the ride since all 4 wheels seem to react and absorb bumps as a system rather than in pairs. The tendency of the front end to jump around on rough pavement has also been eliminated. The bar and related mounting and suspension parts should not make any new noise at all. If it does, something is usually wrong with the placement or installation. It should never rub on anything. I would not recommend any serious off roading as it seriously limits the ability to climb over rocks etc with just one or two wheels.

Guess what I'm saying is that you might want to first check to make sure you received the correct components and then grab a buddy and retry the install using the directions only as a very rough guide. It would really help to have a successfully completed reference vehicle on hand, perhaps theres a nice guy on FTE in Michigan who wouldn't mind killing an hour or so with you.

Sorry about the long winded response but I could not imagine my truck without the bar once it was installed and I think you would appreciate it if it were working the way it should. IMHO, the difference is astonishing. Good Luck.

 

If you need to get rid of it I am thinking about adding one to the wife's EX. I am sure I can order another U-bolt, etc.

PM me if you want.

 

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I strongly recommend you take some time and read the various posts in the various threads about the importance of having a rear sway bar on EX vehicles.

What you are suggesting is absolute nonsence as well as advocating a safety hazzard. Do you really think that all these guys who have contributed their thoughts and ideas on the importance of having a rear sway bar on the EX are wrong, and only YOU are correct ?

Obviously, as others have noted, something must have been VERY wrong with your particular installation.

PLEASE PLEASE go over the various "threads" in this forum and educate yourself on how important it is to have a rear sway bar on your EX.

A word of caution to anyone who might think this fellow is correct:

Ford made a TERRIBLE mistake in letting some EX vehicles out the factory door. I have noted in various threads my astonishment that even the top-of-the line LIMITEDS ( like my otherwise very well equipped '05 V10 4wd Ltd) can be found with no sway bar originally.

How serious an error this omission of a rear sway-bar is, can be found by reading the MANY contributions of so many EX owners in this forum. PLEASE PLEASE read them.

 

When I put on my Icon kit it did not include extended links for the rear bar, mine came stock with it. I am a big enough believer in the rear anti-sway bar (stock or aftermarket) that even though Icon says it is not necessary with their spring pack that I ordered the links anyway so I could put it back on the X.

Now I know the stock bar mounts differently than the Hellwig, but I can't see how it could be binding or making noise, let alone be a problem. The stock bar mounts independantly of the rear shock mounts, maybe you should give OE a try.

 

Relax. He has a 2WD. My 2WD doesn't have a bar either nor do I feel it really "needs" one. My 4WD Excursion, on the other hand, did.

Would there be a benefit if I put one on? Sure but there is no danger of not having one.

 

6686L - Please don't be so dramatic. I've driven this truck for 5 years with and without the aftermarket sway bar that I added. I've made enough evasive maneuvers with it to know that this truck is not as dangerous as you would lead people to believe. I've been trying to chase down a minor handling issue, unfortunately in my case the Hellwig bar contributed to it. I did my research and that is how I ended up with the bar in the first place, don't take me for a moron.

Neal,

I will keep you in mind if I decide for sure to give up. My purpose in posting this is to maybe figure out something I may have overlooked. I followed the directions to the letter and also did the things that LMS suggested. As LMS mentioned I wonder if I got and the wrong bar. The included paperwork is for the EX 2wd and 4wd. I think the lateral clearance with the diff housing is minor and might not be an issue it I can rotate the bar higher on the end links. my biggest concern is longitudinally. I cannot get even close to a 90 degree angle between the bar and the end links. i feel the ends of the bar are about 1"-2" too long for my truck. anyone have a minute to measure from center of bar to center of end link for me?

 

Not only is it safe to not run a rear swaybar on a 4X4, I removed my front one as well when I did the W code upgrade and have not noticed any difference in handling... well that not true, it actually handles far better now without the bar but thats because of the Bilsteins and the W codes.

I can maybe see a need of a rear sway bar for towing purposes but I'll let you know as I'm planning on renting a small excavator to do some work up at the camp.

 

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C'mon - your accusation I may be nuts might fly - but too many other guys posting in this forum disagree with you.

Or is it possible there are more variations of EX spring-rates than we might otherwise think ?

I can tell you this - BEFORE I bought an EX, I read the hell out of this forum, learned a lot, and thus was NOT surprised when I drove my EX back up here in northern Arizona from the Calif. border (bought it in Calif; took delivery here in Arizona to avoid Calif. taxes).

What I found out on that drive (consisting of mixed straight two line high speed, and winding roads over our mountains) is that everything the guys who "post" here about lousy handling without the rear sway-bar is correct. At least it was on my particular EX ( a cream puff 4wd '05 V-10 LTD).

Of course I cannot comment on your particular EX - since, as I suggested above, there may be more variations in spring-rates than we might otherwise have known. Your driving habits may be more gentle than mine, and perhaps your roads out there on that isolated rock do not give you the opportunity to be anywhere near as crazy a driver as I am (you mean an EX isn't an MG-TD sports car...?).

Bottom line- that one drive scared the crap out of me. My EX was a PIG with a capital "P". Wandered, roll-sway - the works. I placed my order for a rear Hellwig that night.

I am NOT saying you guys are nuts. So many variables I have no reason to doubt that SOME of you are satisfied with an EX without sway-bars. I cant resist making a snide remark about your greater knowledge of suspension devices than automotive engineers who first came up with sway bars some 70 years ago.....! I am not aware of an industry-wide program, or any articles in the SAE or ASTM technical journals, recommending removal of sway bars to improve ride and/or handling.

What I am saying is that I just dont get it.

 

Remember that the 4WD Excursion didn't come with a rear sway until 04 and the 2WD never got one. Who planned that? Maybe the automotive engineers you speak of?

I don't think it is different spring rates but the 2WD spring pack is different due to the absence of the snubber bar (traction bar, anti wrap spring whatever...) Plus it sits lower so there is less leverage against the system.

So I stand by my original post. All Excursion could benefit from one. Ford obviously saw the light later in production (maybe from all my emails to them in 01?? ) but I do not think it's unsafe to remove an aftermarket bar.

And you are nuts!

 

My 03 4x4 did not come with one and was prepared for it to be one of the first mods I did to the thing. I then drove it home from South Carolina on 95 and back roads with NO problems which was about 350 miles. I have also towed my boat (10,000 lbs and 33ft) several times even in higher winds (OBX is kinda famous for that) with NO problems. To say it's dangerous to drive without one is a bit dramatic - and while there are a lot of proof points on this board and others doesn't mean the sway bar is always required.

 

Have you driven a 2WD Excursion? If you haven't, well then you can't comment on how they drive now can you? Get back to us once you have driven a 2WD Excursion.

Oh, and try to compare apples to apples.

 

I had an 02 2wd Ex and didn't have one...
but the 03 and 05 4x4's benefitted from one

 

what about the highly trained engineers 10 years ago that didn't put it on in the first place?

yet I'm the one who needs to get educated ???

 

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you are right -

1) i have no idea how a 2wd EX drives. I have had occasion to drive other types of 2wd vehicles, and have had occasion to read various ASTM and SAE tech. papers, along with other misc. automotive hobbyist and engineering publications. Cant recall a single article recommending that you remove the sway bars to improve ride and stability. Cant recall a single article scolding those who install sway bars on vehicles, suggesting that is unnecessary, etc. Perhaps I missed something...?

2) the reason I have no idea how a 2wd EX drives, is that I love in a rural area where a 2wd anything wouldn't meet our needs. I can understand that if you live in a big city where the climate is mild, and never travel, there wouldn't be a reason to spend the extra money to buy and drag around that front drive mechanism, transfer case, etc.

One neighbor who does have a 2wd car used to make fun of me for getting 4wd vehicles. He once asked me if I ever figured out how many miles a year I drive with the 4wd engaged. His point is well-taken. Probably not over a quarter of a mile - rarely more than a few feet at a time.(not including being able to drag our 7,000 lb boat and its 3,500 lb trailer UP slippery boat ramps) but those few feet at a time when being able to get thru a mud-hole was the difference between a long walk home under hostile conditions.

He stopped making fun of me one icy, slushy night, when the EX was able to pull him SIDEWAYS out of a ditch.

Point is - the 2wd EX's may be an entirely different breed of cat from the 4wd's as to handling. I dont know what your driving, road conditions and requirements are - how much weight you tow, how much difference there is in spring rates, etc.

One thing IS clear - I am not the only one who thinks having sway bars is very important for safe operation of an EX.