Hellwig 7789 Front Sway Bar Kit Instruction Manual

https://www.hellwigproducts.com

INSTALLATION INSTRUCTIONS
Front Stabilizer Bar
2500HD, 3500HD Pickup 2wd/4wd incl Dually – 7789

7789 Front Sway Bar Kit

Component Contents

Bag Contents

Standard Tools:

| Ratchet
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| 10mm Socket
| 15mm Socket
| 18mm Deep Socket
| Torque Wrench
| 6mm Socket Wrench

Pro Tip:
End-Link Bushing Installation

When installing the hour glass end-link bushing, remember to use lube. This will not only aid in ease of the hour glass bushing installation, but also reduce squeaking of the suspension.
Place the hourglass bushing and the end link in a bench vice as shown and compress.

Next, take the bushing sleeve and lube the outside of it. Spread the lube around evenly.
Place the end-link with the hourglass bushing already installed and the bushing sleeve in a bench vice as shown and compress.
When done, the final results will look as pictured. Repeat these steps for all endlinks.

General Notes:

These instructions are meant to be a general guide for installing Hellwig Products Co. sway bars. Hellwig Products Co. Inc. assumes no liability for the actual installation process. Consumers should apply common automotive safety practices when working on any vehicles. DO NOT put yourself in a position where if the vehicle should move unexpectedly, you may be seriously hurt.
Hellwig suspension products are designed for ease of installation with standard tools. However, access to a jack, jack stands, and work lights may provide added assistance during your installation. As described in Hellwig installation instructions, many fasteners require proper tension or torque. Use of a torque wrench will verify proper torque for this requirement.

• To ease installation and to properly adjust bar, the weight of the vehicle must be on the suspension, as if driving down the road. Do not Raise Vehicle by frame.
• Before installation, set the E-brake and place wheel chucks under the tires in the appropriate locations to prevent the vehicle from rolling away.
• If you’re not using a 4 post lift when raising the vehicle off the floor to install the anti-sway bar, always fully support the vehicle with jack stands. Ensure that the jack stands are securely positioned, and are rated at or above the weight of the vehicle.
• 2 post lifts are not recommended as the weight of the vehicle must be on the suspension.
• Don’t forget to lube all bushings and end links.
• Always use impact grade sockets with air ratches or impact drivers.
• Holes Are Producing an Interference – apply torque to the nut.
• Nut and Bolt Head are Different Diameters or Shapes – apply torque to the side with the smaller bearing face. This also applies when the hole diameters are different.
• When Clamping Two Different Materials Together – It is always better to apply torque on the component that is against the material with a lower frictional coefficient.
• Long Bolts Are Being Used – When torque is applied to the head of a very long bolt, you may see the effects of torsional wind-up. Applying torque to the nut in this situation will help to avoid that issue.
• There will be many instances where you can apply torque to either the nut or the bolt head. But if one of the above situations applies, remember to follow the guidelines for a better fit and more durable installation

Step 1: Remove Plastic Cover
Remove factory plastic cover utilizing a 15mm socket and ratchet.
*Do not discard factory fasteners, they will be reused.

Step 2: Remove Bottom End Link Nut
For ease of factory sway bar removal, It’s important to note that the lower end-link nut be removed 1st.
Utilize a 18mm socket and ratchet remove the lower end-link nut.
*Do not discard factory fasteners, they will be reused.

Step 3: Remove Factory U Plate bolts
Carefully remove the factory uplates with a 10mm socket and ratchet. Help from a 2nd person to hold and gently lower the sway bar is recommended.
*Do not discard factory breather vent. It will be reused.

Step 4: Remove Upper End Link Nut
Once the factory sway bar is removed from the truck, disassemble the end-link from the sway bar. Using a 6mm socket wrench, hold the end-link bolt in place while using a 18m socket and ratchet to remove the upper end-link nut.
*Do not discard factory fasteners, they will be reused.

Step 5: Lubricate Bushings
Apply ample amount of lubricant to the inside of each D-Bushing. Spread it evenly throughout the entire inside of the D-Bushing. Install the D-Bushings on the bar in the approximate location of mounting. (usually about half a packet of lube per D-Busing is sufficient).

Step 6: Attach upper End Link Bolt
Before installing your new Hellwig sway bar, attach the end-link to the sway bar. Using a 6mm socket wrench, hold the end-link bolt in place while using a 18m socket and ratchet to tighten the upper end- link nut.
• Torque BEFORE installing sway bar back in truck. See Torque specs for torque value.

Step 7: Attach U-Plates
Attach your new Hellwig sway bar by taking the Hellwig provided U Plates and slide them over the provided lubricated D-Bushings. Raise the bar up to the factory mounting location.
Install the flat washers onto the factory bolts and thread into the mounting holes. Tighten down using a 10 mm socket and ratchet.
Help of a 2nd person will ease installation.
• Tighten but do not torque, allowing the bar to rotate up and down.

Step 8: Attach Lower End Link
When attaching the lower end-link, do not forget the keyed wishbone. This will hold lower end-link bolt in place while tightening the nut. Orientate wishbone as seen in the photo.
Tighten down the end-link nut using a 18mm socket and ratch- et.
• Tighten but do not torque.

Step 14: Torque
Before torquing the fasteners, check your sway bar is evenly spaced left to right.
Once it’s been determined to be in correct position. Revisit each of the fasteners and torque to the specified torque table below.

Step 15: Reinstall Plastic Cover
Using the saved bolts from step one, reinstall factory plastic cover utilizing a 15mm socket and ratchet. Torque to 30 Nm.

1. Fasteners:
   All Hellwig supplied fasteners must be utilized and installed in accordance with the installation instructions and apply torque to the specifications as defined. It is recommended to use Anti-Seize (not supplied) on all threads upon installation.

2. Modification:
   Do not attempt to modify the vehicle or the Hellwig product you are installing. If a problem is encountered, stop and call Hellwig Products (1-800-367-5480) for support. Hellwig Products Company will not be responsible for any damage or injury resulting from any modification or alteration. Do not use this document for custom fabrication, as it may not show all parts or structural components.

3. Drilling:
   Most Hellwig products do not require drilling and or tapping for installation. If drilling is defined as required, use caution when drilling a vehicle. Failure to review an area to be drilled, may result in personal injury and/or injury to other as well as vehicle damage.

4. Eye Protection:
   Always wear safety glasses or goggles during the installation process to avoid personal injury.

5. Maximum Towing/Carrying Capacity:
   User should never exceed the vehicle manufacture’s maximum tow and weight rating. Failure to follow these guidelines will void the Hellwig warranty and may result in personal injury and/or injury to others as well as vehicle damage.

6. For California Residents Only–Prop 65 Warning:
   Some products may contain chemicals such as DEHP, which can cause cancer, birth defects or other reproductive harm. For more info go to www.p65warning.ca.gov

7. Checks after Install:
   After installing your new Hellwig sway bar it is recommended to bounce the vehicle, check for clearances, and if all looks good test drive the vehicle. Check the fasteners regularly thereafter. Ensure no damage is being done to the sway bar or your vehicle.

7786 · 1-800-HELLWIG (435-5944)
Local559-734-7451
techsupport@hellwigproducts.com
Rev 1.1 · 6/24/2022 · 10

Documents / Resources

| Hellwig 7789 Front Sway Bar Kit [pdf] Instruction Manual
2020-2023 GMC Silverado-Sierra 2500HD-3500HD, 7789 Front Sway Bar Kit, 7789, 7789 Front Sway Bar, Front Sway Bar Kit, Front Sway Bar, Sway Bar
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