HELLWIG PRODUCTS R-7780 Rear Stabilizer Bar Instruction Manual

HELLWIG PRODUCTS R-7780 Rear Stabilizer Bar

Product Information:

The Hellwig Rear Stabilizer Bar is a high-quality product designed to provide load control for various vehicles including trucks, RVs, muscle cars, and military vehicles. Hellwig Products Company, located in Visalia, California, has been producing components for vehicle load control since 1946. The company is family-operated, ISO9001 certified, and takes pride in developing, testing, and manufacturing products in the USA.

Product Usage Instructions

Before starting the installation

• Set the parking brake and chock the wheels for safety.

Note:

• Ensure that the weight of the vehicle is on the suspension during installation.
• Do not raise the vehicle by the frame.
• This unit is designed to replace the factory-installed rear anti-sway bar or can be added if the rear anti-sway bar is not factory supplied.
• The kit includes lock nuts that need to be tightened with a wrench after being started by hand.

Installation Steps:

1. Remove the factory-installed rear anti-sway bar (if equipped) and all factory-supplied hardware.

2. Mount the square-shaped U-bolts around the frame. Bolt the clevis brackets to the U-bolts using the supplied 1/2 washers and nuts.

3. Insert hourglass bushings into the loops of the end links.
   Lubricate bushings with supplied lubricant to aid installation.
   Install sleeves into hourglass bushings.

4. Assemble end links together with the 9/16 jam nut on the threaded portion of the end link. Leave loose for adjustment later.

5. Loosely attach end links to clevis bracket using a 7/16 x 2-3/4 long bolt and lock nut. Leave loose for adjustment later.

6. Install round U-bolts over the axle, making sure they are under any brake lines, wires, or hoses to avoid pinching or crushing when tightened.

7. Lubricate and install d-bushings on the sway bar. Install U-plates over the d-bushings.

8. Attach the sway bar to the lower bushings on the end links using 7/16 x 2-3/4 bolts, washers, and locknuts. Leave loose for adjustment later.

9. Rotate the sway bar into position and attach it to the axle by placing the legs of the U-bolts through the holes.

Maintenance and Inspection:

Your Hellwig Suspension Product is built to last, but routine inspection is necessary for proper functioning. Regularly inspect your Hellwig installation for secure hardware, tight fitting brackets, and bushings. If you are unable to perform this inspection, have a professional mechanic inspect it as described.

INSTALLATION INSTRUCTIONS

Rear Stabilizer Bar
Thank you for purchasing a quality Hellwig Product.

Hellwig Products Company, located in Visalia, California was founded in 1946 with solutions for load control of loaded passenger cars. The family operated company produces components for trucks, RVs, muscle cars and military vehicles. Hellwig is ISO9001 certified and is proud to develop, test and manufacture products in the USA.

TORQUE TABLE

• BOLT SIZE: 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs.
• SAFETY: BEFORE STARTING YOUR INSTALLATION, BE SURE TO SET PARKING BRAKE AND CHOCK THE WHEELS.
• NOTE: TO EASE INSTALLATION AND TO PROPERLY ADJUST BAR, THE WEIGHT OF THE VEHICLE MUST BE ON THE SUSPEN- SION, AS IF DRIVING DOWN THE ROAD. DO NOT RAISE THE VEHICLE BY FRAME.
• NOTE: THIS UNIT IS DESIGNED TO REPLACE THE FACTORY INSTALLED REAR ANTI-SWAY BAR OR AS AN ADDITION IF THE REAR ANTI-SWAY IS NOT FACTORY SUPPLIED.
• NOTE: THIS KIT INCLUDES LOCK NUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER BEING STARTED BY HAND.

1. Remove the factory installed rear anti-sway bar (if equipped) and all factory supplied hardware.
2. Mount the square shaped U-bolts around the frame. Bolt the clevis brackets to the U-bolts using the supplied 1/2” washers and nuts.
3. Insert hourglass bushings into the loops of the end links. Lubricate bushings with supplied lubricant to aid installation. Install sleeves into hourglass bushings.
4. Assemble end links together as shown in Photo 3 with 9/16” jam nut on threaded portion of end link. Leave loose for adjustment later.
5. Loosely attach end links to clevis bracket using 7/16” x 2-3/4” long bolt and lock nut. Leave loose for adjustment later.
6. Install round U-bolts over axle as shown in Photo 1. Make sure the U-bolts are under any brake lines, wires, or hoses on the axle to avoid pinching or crushing when tightened.
7. Lubricate and install d-bushings on sway bar. Install U-plates over the d-bushings as shown in Photo 2.
8. Attach sway bar to lower bushings on end links using 7/16 x 2-3/4” bolts, washers, and locknuts. Leave loose for adjustment later.
9. Rotate sway bar into position and attach to axle by placing the legs of the U-bolts through the holes in the saddle brackets and U-plates. Fasten with 1/2” washers and double nut as shown in Photo 2. Leave loose for adjustment later.
10. With the sway bar properly aligned, ensure that all the vehicle components have the proper clearance, and no wire or hoses will be crush or pinched when tightened.
11. Torque U-bolts to 50-60 ft-lb.
12. Torque end link fasteners to 35-40 ft-lb.
13. Bounce the vehicle, check for clearance on all undercarriage components; exhaust, wires, shocks, brake, and fuel lines. Test drive the vehicle and recheck for clearance and installation alignment.
14. The sway bar arms have three mounting holes. Mounting the sway bar on the outer hole is the nominal position. For firmer settings, use the inner holes. We recommend starting with the outer mounting hole until you are accustomed to the vehicles new handling characteristics. Select the mounting point that best fits your driving style.
15. After one week of driving recheck your installation. Recheck on a regular basis thereafter.

ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM

Maintenance and Inspection:
Your Hellwig Suspension Product is built to last. However, as with all vehicle systems, it requires routine inspection. Inspect your Hellwig installation looking for secure hardware and tight fitting brackets and bush-ings. If you do not perform this inspection, have your professional mechanic inspect as described.

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