Hellwig 7830 Rear Stabilizer Bar Installation Guide

SUSPENSION PRODUCTS
INSTALLATION INSTRUCTIONS
Rear Stabilizer Bar
Ford Bronco – 7830

7830 Rear Stabilizer Bar

| Component Contents| | | Bag Contents|
---|---|---|---|---|---
Number| Part Name| Quantity| Number| Part Name| Quantity
1| Sway Bar| 1| 1| 7/16-20 x 2 – 1/2” Bolt| 2
2| U-Plates| 2| 2| 7/16-20 x 6” Bolt| 2
3| D-Bushings| 2| 3| 7/16” Washer| 10
4| Axle Saddle Brackets| 2| 4| 5/8” Large Washer| 2
5| 1/2-20” U-Bolts| 2| 5| 1/2” Washer| 4
6| Female End-Links| 2| 6| 9/16-18” Jam Nut| 2
7| Male Offset End-Links| 2| 7| 7/16-20” Stover Nut| 4
8| Instruction Sheet| 1| 8| 1/2-20” Hex Nut| 8
9| Warranty Form| 1| 9| Spacer| 2
10| | | 10| Hourglass Bushing Sleeve| 4
11| | | 11| Hourglass Bushing| 4
12| | | 12| Bushing Lube| 2

Standard Tools:

| Ratchet
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| 5/8” Socket
| 3/4” Deep Socket
| Torque Wrench
| 3/4” Socket Wrench
| 11/16 Socket Wrench
| 13/16 Socket Wrench
| 7/8 Socket Wrench
| Stepper Drill Bit
| Electric Drill

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 thesuspension.| Place the hourglass bushing and the endlink 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 Axle Breather Vent

Removing the factory axle breather  vent will allow the break lines to be more flexible and out of the way for installing the U-Bolts.
*Do not discard factory breather vent. It will be reused.

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Step 2:Install U-Bolts and Axle Saddle Brackets
Gently lift the break lines out of the way to slip the U-Bolts underneath.
Followed by installing the saddle brackets on the axle over the UBolts.

| Step 3: 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).
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Step 4: Install U-Plates Attach your new Hellwig sway bar by taking the Hellwig provided UPlates and slide them over the provided lubricated D-Bushings. Raise the bar up to the axle saddle brackets and mount the sway bar to the U-Bolts. Install a 1/2” washer first followed by a hex nut. Utilize a 3/4” deep socket and ratchet, threading ONE hex nut down the U-Bolts evenly. Alternating from top to bottom hex nut. • Tighten but do not torque, allowing the saddle bracket and U-Bolt to rotate around the axle tube, if necessary.
| Step 5: Assemble EndLinks Take the hour glass bushings and gently lube the outside of the bushing. This will also assist in ease of installation. You can reference the end – link bushing installation pro tip guide on how to install them on page 3. Thread the male and female ends together. Final length will be determined later on.
Step 6: Attach End-Link to Sway Bar

Attach the male offset end-link side to the forward most hole for initial use. Using the following hardware
• 7/16-20 x 2-1/2” bolt
• 7/16” washers
• 7/16-20” stover nut.
Tools required are
• 11/16” socket wrench
• 5/8” socket and ratchet
Tighten but do not torque, allowing the end-link to still rotate around the bolt.

| Step 7: Picking a Location to Drill End-Link Upper Mounting Hole

With the end-links attached, rotate your axle so the arms are parallel to the ground.
Adjust the length of your end link until you’re satisfied with the upper end- link bushing location along side the frame. With a 7/8” socket wrench, lock end-link in place with the jam nut. Using the sleeve in the bushing as a guide, mark the hole location to drill on the frame.

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Step 8: Transfer Mounting Hole Location Using a square and straight edge, draw a vertical line down to the bottom of the frame. Measure this distance. Draw a perpendicular line across the bottom of the frame. Followed by a vertical line on the other side, same length as the vertical line you just measured. Make sure all electrical and fuel lines are out of the way from drilling.

Step 9: Drill Mounting Holes Utilizing an electric drill and stepper bit, drill the hole on the outside of the frame to 15/32” (0.468”). Drill the hole on the inside of the frame to 11/16” (0.688”). †Both holes are different sizes. DO NOT make them same size. *** If you have stock height lift, you may want to drill closer to the top of your frame. If you have a tall lift around 5”, you may want to drill closer to the bottom. To keep the sway bar parallel to the ground.
Step 10: Attach End-Links
Attach the female end-link to the frame using the following hardware

• 7/16-20 x 6” bolt
• 7/16” washers
• 7/16-20” stover nut.
• 5/8” Large Washer
• Spacer

Tools required are

• 11/16” socket wrench,
• 5/8” socket and ratchet
  Install the large washer over spacer tube and check that spacer tube is 1/32” (.031”) below the surface of large washer. Failure to do this will

Continue Step 10: result in insufficient preload and noise. File or grind end of spacer tube to achieve proper length.
Install all upper end-link to the frame after all modifications have been made.
Tighten, but do not torque yet.
Double check sway bar is parallel to the ground. End-Links may need to be readjusted and/or saddle brackets  rotatedaround the axle.
Optional Severe EndLink Mounting For Severe mounting option, weld the spacer to the frame and do not use washers on the welded side. Be sure to follow proper welding procedure or hire a professional to do the welding. Check surrounding area for fuel lines, electrical, ect that may get damaged during welding and protect them.

Step 14: Torque Before torquing the fasteners, check your sway bar to be as parallel with the ground as possible. End links may have to be removed and readjusted (longer/shorter). After threading the first nut is all the way down on the top and bottom of the axle bracket, torque to recommended torque in chart. Now add the 2nd hex nut, which will act as a jam nut. Hold the first nut in place with a 3/4” socket wrench and torque to recommended torque in chart. Revisit each of the fasteners and torque to the specified torque table below.

Reinstall the axle tube breather vent. We found using a spacer helped keep the brake lines clear of the U-bolts. If you bend the brake lines, be sure not to kink them.

WARNING

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. 2. 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.
3. Eye Protection: Always wear safety glasses or goggles during the installation process to avoid personal injury.
4. 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.
5. 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
6. 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)
Local 559-734-7451
techsupport@hellwigproducts.com
Rev 1.1
6/14/2022
12

https://www.hellwigproducts.com

Documents / Resources

| Hellwig 7830 Rear Stabilizer Bar [pdf] Installation Guide
1966-1977 Ford Bronco 4WD w-0-4 Lift, 7830 Rear Stabilizer Bar, 7830, 7830 Stabilizer Bar, Rear Stabilizer Bar, Stabilizer Bar, Stabilizer
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