Hellwig 7794 Rear Stabilizer Bar Instruction Manual
- June 12, 2024
- Hellwig
Table of Contents
Hellwig 7794 Rear Stabilizer Bar
Product Information
The Rear Stabilizer Bar is designed for the Dodge 1500 TRX – 7794 model. It includes various components such as Sway Bar, U-Plates, D-Bushings, Axle Saddle Brackets, U-Bolts, End-Links, Collar Clamps, and more. The package also includes the necessary bolts, nuts, washers, and lubricant for installation. The product comes with an Instruction Sheet and Warranty Form.
Component Contents /Bag Contents
Number /Part Name /Quantity
- Sway Bar/ 1
- U-Plates/ 2
- D-Bushings/ 2
- Axle Saddle Brackets/ 2
- 1/2-20” U-Bolts/ 2
- Female End-Links/ 2
- Male End-Links/ 2
- Collar Clamps/ 2
- Instruction Sheet/ 1
- Warranty Form /1
- 7/16-20 x 2 – 3/4” Bolt/ 2
- M10-1.5 x 65 Flange Bolt/ 2
- 7/16” Washer/ 10
- 9/16-18” Jam Nut/ 2
- 1/2-20” Hex Nut/ 8
- 7/16 – 20 Stover Nut/ 2
- Blue Thread Lock/ 1
- Hourglass Bushing Sleeve/ 4
- Hourglass Bushing/ 4
- Bushing Lube/ 2
Standard Tools
- Ratchet
- 15mm Socket
- 3/4” Deep Socket
- 11/16” Combination Wrench
- 11/16” Socket
- 5/8” Combination Wrench
- 7/8 Combination Wrench
- Torque Wrench
ADJUSTABLE SWAY CONTROL
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 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
- Exposed threads on the male threaded end-link may be painted to help the exposed metal resist rusting.
Installation Instructions
Step 1: Install Hourglass Bushings and Sleeves
- For pro tip on how to install hourglass bushings and sleeve, please refer to the End-Link Bushing installation.
Step 2: Attach End-Links
Attach both female end-links to the threaded bracket on the frame using the M10-1.5x65mm bolts, washers, and Loctite.
Utilize Tools required are:
- 15mm socket and ratchet
Tighten but do not torque.
Step 3: Install Male End- Links
- Thread the Jam nut down the threaded shaft of the male endlink.
- Next, thread the male end-links into the female end-links. Stop when at desired length, when the bar would be approximately parallel with the ground. Later steps we’ll fine tune this.
Step 4: Attach Sway Bar to End-Links
Attach the center hole of each end of the sway bar to the end-links using the following hardware
- 7/16” bolt
- Washers
- 7/16” Stover Nut
Tighten finger tight and let the sway bar hang down. Stover nut is a locking nut, thus, do not use any tools to tighten in case you must remove to readjust endlinks. Stover Nuts should not be reused once tightened down
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: Install U-Bolts and Axle Saddle Brackets
- Gently lift the break lines out of the way to slip the U-Bolts underneath.
- U-Bolts may fit a little tight. That’s ok, push until the U-Bolt seats as close as possible on the axle tube.
- Place the saddle brackets over the U-Bolts to use as a guide to rotate the two piece into position as seen.
- The saddle bracket more than likely won’t stay on and will need to be held into place with one hand while installing the U-Plates with the other in the next step.
Step 7: Install U-Plates
- Attach your new Hellwig sway bar by taking the provided U-Plates 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 ONE hex nut. Utilize a 3/4” deep socket and ratchet, threading ONE hex nut down the U-Bolt leg evenly.
- Alternating from top to bottom hex nut. Repeat for other side
- Tighten but do not torque, allowing the saddle bracket and U-Bolt to rotate around the axle tube, if necessary.
Step 8: Check for Parallel
- Now with your bar mounted into position, check that the bar is parallel to the ground or slightly pointed up. If you must remove the endlinks, do so one at a time, from the sway bar to shorten or lengthen each end-link. You may have to remove both if adjustment is too great in either direction.
- Reinstall the hardware, this time using 5/8” combination wrench and 11/16” socket and ratchet. Run the jam nut all the way up to the female end-link and lock into place.
- Tighten down but do not torque.
Step 9: Install Collar Clamps
- Now that the bar is level, check that the bar is centered as possible and install the Hellwig provided collar clamps with the provided hex key.
Step 10: Torque
- With the first four nuts threaded all the way down om the axle saddle brackets, 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” combination wrench and torque to recommended torque in chart.
- Revisit each of the remaining fasteners and torque to the specified torque table.
Note: These values are only correct when Loctite is used.
Step 14: Torque Chart
Description /Nm /Lb-Ft
- Sway Bar U-Plate 1st and 2nd nut /64
- Sway Bar End Link Nut /41
- Frame End Link Bolt /54 /40
Precautions
WARNING
- 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.
- 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.
- 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.
- Eye Protection:
- Always wear safety glasses or goggles during the installation process to avoid personal injury.
- 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.
- 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
- 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.
Contact
- 1-800-HELLWIG (435-5944)
- Local 559-734-7451
- [email protected]
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Documents / Resources
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Hellwig 7794 Rear Stabilizer
Bar
[pdf] Instruction Manual
7794 Rear Stabilizer Bar, 7794, Rear Stabilizer Bar, Stabilizer Bar, Bar
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