Hellwig 7626 User Manual

559-734-7451 800-367-5480 FAX [phone]

INSTALLATION INSTRUCTIONS

Rear Stabilizer Bar

94-02 DODGE 4X4 W1500-W3500 TRUCK

INCLUDING DUAL WHEELS

Thank you for purchasing a quality Hellwig Product.

REAR VIEW

PASSENGER SIDE

7626 ( (R 7626 ) 01/13/04

ATTENTION INSTALLER: BE SURE THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET, ALL

559-734-7451 800-367-5480 FAX [phone]

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 SUSPENSION, AS IF DRIVING DOWN THE ROAD. DO NOT RAISE THE VEHICLE BY THE FRAME.

NOTE: THIS UNIT IS DESIGNED TO MOUNT TO THE BOTTOM OF THE AXLE SHOCK MOUNTS WITH THE ARMS OF

THE BAR FACING TOWARDS THE FRONT OF THE VEHICLE. IT WILL BE NECESSARY TO REMOVE THE BOTTOM OF
THE SHOCK FROM THE LOWER SHOCK MOUNTS. IT MAY ALSO BE NECESSARY TO DRILL TWO (2) HOLES IN THE
BOTTOM OF THE FRAME RAIL ON SOME VEHICLES.

NOTE: THIS KIT INCLUDES LOCKNUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER BEING STARTED

BY HAND

1. Install the D-shaped poly –bushings onto the bar on each side of the center hump. These bushings will
align with the shock mounts on the axle.

2. With the shocks removed from the lower axle mounts. Place the mounting bolts provided into the holes in
the bottom of the shock mounts so that the threads are pointing downward. The hole that is directly below
the shock will use the special clearance flat head bolt provided. The square shoulders under the bolt head
should press into the hole, which will not allow the bolt to turn.

3. As per diagram. There are two (2) three hole flat plates included in this kit, one (1) small and one (1) large.
.The small three hole plate mounts to the bottom of the passenger side shock mount so that the third hole is
to the rear of the axle. For vehicles with the Dana 80 rear axle use the large three (3) hole plate. This
will align the bar across the axle. Use the thick two (2) hole plate on the driver’s side to space the bar
downwards to be level with the passenger side.

4. Place the U-plates over the bushings on the bar and attach to the plates with hardware provided. Leave
loose at this time to allow for adjustment later.

5. Assemble the end-links by installing the sleeve type poly-bushing (it may be necessary to lightly grease
the poly-bushing and steel sleeve before installing) into the tube welded to the end of the link. Place the
small steel sleeve inside the bushing to complete this end of the assembly. See Diagram in instruction
sheet insert (R-344). Mount the small U-shaped bracket to the end of the bar. Then match up the holes in
the end-links to the length needed that will allow the arms of the bar to be as level with the frame as possi­ble.

6. Rotate the bar so that the brackets contact the bottom of the frame. Align the end-links in as straight up and
down position as possible. The end-links will show the position where the frame brackets will contact the
bottom of the frame rails.

7. With the frame brackets up against the frame and the bar centered and all adjustments locating the bar un­der the vehicle properly. If your vehicle does not have the factory mounting holes. Mark the frame with the
centers of the frame bracket mounting holes and drill two (2) 7/16” holes in the bottom of each frame rail.
Be sure to move any wires or lines from inside the frame to avoid any possible damage.

8. Mount the frame brackets to the frame with hardware provided. Place the small flat two (2) hole plate in­side the frame rail above the frame brackets. Torque all frame and axle mounting hardware to the specified
rates. Reinstall the shocks in their mounts and torque.

9. Bounce the vehicle and check for clearance on all carriage components, shocks, exhaust etc…….

Drive the vehicle for a short distance then recheck your installation and periodically thereafter.

WARNING AND NOTE CARDS AND THE WARRANTY FORM.

7626 ( R 7626 ) 01/13/04