Hellwig 7810 User Manual
INSTALLATION INSTRUCTIONS
REAR STABILIZER BAR
88-00 C/K 3500 DUALLY
Thank you for purchasing a quality Hellwig Product.
1
VEHICLES FRAME
3
BOTTOM VIEW
SWAY BAR MOUNTING LOCATIONS OF U-PLATE,
D-BUSHING, U-BOLTS AND SADDLE BRACKETS
REAR VIEW
SWAY BAR
VEHICLES FRAME
J-BOLT
WASHER & END
LINK BUSHINGS
AXLE`
END LINK ASSY
SIDE VIEW
4
SWAY BAR IS FLAT & EVEN
WITH THE GROUND & END
LINKS STRAIGHT UP AND
DOWN
OUTER FRAME BRACKET INNER FRAME BRACKET
SLEEVE
LOCK NUT
2
U-BOLT, SADDLE BRACKET
D-BUSHING & U-PL`ATE
FRONT OF VEHICLE
7609 ( R-375 ) 06/08/07
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
TIRES.
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 VEHICLE BY FRAME.
1. As per photo ( 1 ) place the U-bolts over the axle tubes just inside of the lower shock mount brackets.
Be sure to put the U-bolts under any brake lines, wires or hoses on the axle to avoid any damage. The
brake lines may have to be slightly bend to allow for clearance for the U-bolts.
2. Place the D-bushings on the sway bar at the flat areas between the center hump and the arms. See
photo ( 1 ).
3. Locate and position the Saddle brackets on the U-bolts that are on the axle tubes. Position the U-plates
on the D-bushings on the sway bar. Raise the sway bar up to the axle, insert U-bolts thru the slotted
holes on the U-plates. Attach with mounting hardware supplied. Tighten just enough to support the
sway bar to the axle. ( Leave loose at this time to allow for adjustment later ).
4. Looking at photo ( 2 ) assemble the end link assemblies. End link bolt, washer, poly bushing insert
thru outer frame bracket. Position the outer frame brackets, attach the inner frame brackets with
mounting hardware provided. Leave loose at this time to allow for adjustment later. Insert ploybushing, washer, steel sleeve, washer, poly bushing. Insert thru eye of sway bar arm, poly-bushing,
washer and tighten with lock washer provided. Tighten just slightly that the poly-bushings start to
bulge. Over tightening can damage the poly-bushings. Do the same on opposite side. ( Check for
clearance on wires, fuel or brake lines that run thru the vehicles frame ).
5. With the sway bar attached at the axle and end link assemblies attached to the frame brackets. The
frame brackets can be moved forward or backwards and the U-bolts at the axle can also be rotated to
allow the sway bar to be flat against the ground and the end links as straight up and down as possible.
See photos ( 3 & 4 ).
6. With the sway bar properly aligned check for clearance on all under carriage components. Check for
clearance on electrical wires, exhaust, brake and fuel lines. Torque all mounting hardware to specified
rates.
7. Using the J-bolts attach the bottom of the outer frame brackets to the lower lip of the vehicles frame.
Tighten top specified rate.
8. Bounce the vehicle check for clearance on all under carriage components. Test drive your vehicle recheck your installation re-adjust as needed. Re-check your installation on a monthly regular basis
thereafter.
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION
7609 ( R-375 ) 06/08/07
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