Hellwig 7891 User Manual

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INSTALLATION INSTRUCTIONS

7891 Rear Stabilizer Bar

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR

INSTALLATION

Heat Shield

1

2

Brake Line

Clip

Tie Strap

SAFETY:

TIRES.

NOTE:

BE ON THE SUSPENSION, AS IF DRIVING DOWN THE ROAD.

NOTE:

BAR TOWARD THE REAR OF THE VEHICLE. THE HUMP SHOULD TILT SLIGHTLY DOWNWARD.

NOTE:

STARTED BY HAND.

1. Remove spare tire from vehicle before beginning installation of sway bar.

2. As shown in photo 1, place D-shaped poly-bushings onto straight areas of the bar on each side of center hump.
After installing D-bushings onto bar, place U-plates on D-bushings. The sway bar will be installed with the hump
tilted down, away from the spare tire.

3. Place U-bolts on axle tubes next to casting as shown in photos 1, 2. When installing U-bolts, be sure to put U-

bolts under any brake lines, wires or hoses on the axle to avoid any possible damage.

4. Before installing saddle brackets, remove passenger side brake line from clip and reposition brake line so
that it will clear the saddle bracket as shown in photo 2. Secure brake line with tie strap.

5. Place saddle brackets on axle by inserting legs of U-bolts into the holes in saddle brackets. Saddle brackets must be
installed so that one leg of the saddle bracket is located on the cast center section with the leg just inside the raised
lip on the casting. See photos 1,2.

6. Raise bar and place D-bushings on saddle brackets by inserting legs of U-bolts through holes in U-plates. Install
flat washers and hex nuts provided on U-bolts. Do not use locknuts provided in kit on axle U-bolts. LEAVE

LOOSE AT THIS TIME to allow for adjustment later.

BEFORE STARTING YOUR INSTALLATION, BE SURE TO SET PARKING BRAKE AND CHOCK

TO EASE INSTALLATION AND TO PROPERLY ADJUST BAR, THE WEIGHT OF THE VEHICLE MUST

DO NOT RAISE VEHICLE BY FRAME.

THIS UNIT IS DESIGNED TO MOUNT TO THE REAR OF THE AXLE TUBES WITH THE ARMS OF THE

THIS KIT INCLUDES LOCK NUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER BEING

7891(R-7891) 07/09/10

Note: Heat shield not shown

9/16” Jam Nut

7/16 X 2-1/4” Bolt

Screw

Heat Shield

U-bolt

Clevis

1/2 X 1-1/2” Bolt

3

4

7. Attach clevis to end of sway bar with 1/2 x1-1/2” bolt, thick washer and locknut as shown in photo (3).. Torque to 50 ft-lb.

8. Assemble end links as shown in photos with 9/16” nut on the threaded half. Leave loose for adjustment. Insert hourglass

bushing first and then sleeve into the loops of the end link assembly. Lubricate the bushing and sleeve to ease assembly

9. Remove the 2 screws attaching the spare tire heat shield to the passenger side frame rail. Save for use later.

10. Locate existing spare tire crossmember on vehicle frame. Place square U-bolt over frame rail just behind crossmember with

legs of U-bolt pointing downward. On passenger side the inside leg of the U-bolt will fit between the heat shield and the rail

as shown.

11. Insert legs of U-bolt into slotted holes of the hanger brackets. Install hanger brackets with clevis inboard of frame rail and

toward front of vehicle as shown in photo 3. Attach using 1/2” lock nuts. LEAVE LOOSE for adjustment later.

12. Place end link into clevis with offset inboard. Attach end link to clevis with 7/16 X 2 1/4” bolt on driver side On passenger

side use the 7/16 x 2-1/2” bolt to attach end link and offset bracket to clevis as shown in photo 5 to space the heat shield

away from the end link. LEAVE LOOSE for adjustment later.

13. Attach end links to clevis on sway bar with 7/16 X 2-1/4” bolts and locknuts as shown on photo 3.

14. With sway bar loosely mounted, work bar back and forth in D-shaped poly bushings to center bar.

7891(R-7891) 07/09/10