Hellwig 7869 User Manual

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INSTALLATION INSTRUCTIONS

Rear Stabilizer Bar 7869

1966-77 Ford Bronco

Thank you for purchasing a quality Hellwig Product.

Attach end link to forward-

1

most hole for initial use

U-Plate

U-Bolt

2

7869 (R-7869) 07/13/2011

3 4

Saddle

Bracket

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TORQUE TABLE

Bolt Size 3/8”— 35 ft lbs * Bolt Size 7/16”— 45 ft lbs* Bolt Size 1/2”—75 ft lbs *Bolt Size 9/16”— 90 ft lbs

SAFETY: BEFOREBEGINNING INSTALLATION BE SURE TO SET THE PARKING BRAKE AND CHOCK THE

WHEELS.

NOTE: TO EASE INSTALLATION AND PROPERLY ADJUST THE 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 KIT REQUIRES DRILLING THE FRAME RAIL AND POSSIBLE RELOCATION
OF FUEL AND BRAKE LINES. INSTALLER MUST ENSURE THAT THE SWAY BAR KIT
WILL NOT INTERFERE WITH ANY FUEL OR BRAKE LINES, HOSES, ELECTRICAL WIR­ING OR OTHER CHASSIS COMPONENTS.

1. Lubricate the D shaped bushings and place them onto the straight areas of the bar on each side of the center hump as close to
the outside bend as possible.

2. Hold bar up to the axle and locate the position on the axle tubes to mount the u-bolts. Be sure to put the U-Bolts Under

Any Brake Lines, Wires or Hoses on the Axle to Avoid Any Possible Damage.

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5 6 7

3. Place the saddle brackets onto the U-Bolts on the axle tubes. Place the U-Plates over the D shaped bushings on the bar and
attach the bar to the U-Bolts and saddle brackets with the flat washers and stover nuts provided. The U-Plates will be rotated
up on the axle to match PHOTO 1 and PHOTO 3. LEAVE LOOSE AT THIS TIME to allow for adjustment later.

6. Position sway bar on axle so that it clears all frame mounted components including fuel tanks, brake lines, fuel lines, etc.
Sway bar can be rotated back and forth on axle to maximize clearance.

7. Assemble end links by inserting hourglass bushings into the end link hoop and then inner sleeve into the bushing. Fully
lubricate bushings before installation. Install 9/16” nut on threaded section of end link before assembling the two halves
together as shown. IMPORTANTNOTE - The end link threads are NOT powder coated so that the end links can be

threaded together. Toprevent corrosion, it is advised to lightly coat the exposed threads with black spray paint after
adjusting to desired length.

8. Attach end links to the center hole of the sway bar and align end links for best fit as shown in PHOTO 4. IMPORTANT
NOTE – Center hole position is only for determining hole location. The end link will be moved to the outer hole prior

to initial use.

9. The end links should be located as shown in PHOTO 4 so that the arms of the sway bar are parallel with the ground. When
satisfied with their location, mark location of holes for the end links.

10. Prepare to jack up vehicle by placing wheel chocks on the front wheels. After the rear of the vehicle has been raised, sup-
port frame on jack stands and remove rear wheels.

11. Transfer hole location to inner edge of frame rail. A piece of card board can be used by marking the location of the hole on
the cardboard and transferring the location to the outer rail. Drawing a line on the frame square to the frame rails will keep
the hole location square. See PHOTO 5,6&7.

12. Review end link mounting detail before drilling holes. BEFORE DRILLING ANY HOLES IN THE RAIL—

DISCONNECTBATTERY AND RELOCATE AND PROTECT ANY FUEL OR BRAKE LINES, WIRING, ETC.
THAT MAY INTERFERE WITH THE DRILL BIT OR SWAY BAR INSTALLATION.

13. Drill a 15/32 (.468) hole through BOTH walls of the frame. Make sure holes are square to one another when drilling holes.

14. Drill an 11/16 (.688) hole through INNER wall of frame ONLY.

15. Insert 7/16 X 6 bolt through rail as shown in PHOTO 8. Insert spacer sleeve into hole so that it is flush with the outboard
wall of the frame. For severe duty it is recommended that the spacer tube be welded to the outer frame wall. If the spacer is

to be welded, review severe service end link detail on page 4 and skip to line 17. If any welding is to be done, the in­staller must ensure that all hazards (fuel, electrical, etc) are eliminated and that fuel tanks, fuel lines, brake lines,
wiring, etc. are not affected by the welding operation.

16. Install 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 result in insufficient preload and noise. File or grind end of spacer tube to achieve proper length. SEE
PHOTO 9.

17. Remove bolt and spacer and attach end link to frame as shown in detail and PHOTO 10. Applications with welded spacer do
not require the washers on the inboard side of frame. Torque end link bolts to 35-40 ft-lb.

18. Replace rear wheels and torque lug nuts to factory specification. Lower vehicle so that the full weight of the vehicle is on the
suspension.

19. Tighten axle u-bolts to 35 ft-lb.

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Washer

End Link

8 9 10

20. Bounce the vehicle checking for clearance on all under carriage components: fuel tank, shocks, differential, brake and
fuel lines, etc. Test drive the vehicle and recheck all clearances and the installation alignment. Adjust as needed. Re-check your

installation after one week of driving and periodically on a regular basis.

21. The sway bars arms have three mounting holes. Mounting the sway bar on the outer hole (forward-most) is the nominal

position. For a firmer setting, 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.

Sleeve Tube

ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION

SHEET, ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM

7869 (R-7869) 07/13/2011