Hellwig 7892 User Manual

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

INSTALLATION INSTRUCTIONS

Rear Stabilizer Bar 7892

GM 2500HD-3500HD 2WD-4WD

4”-6” lift kit applications (4”-6” front/2”-4” rear)

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR

Remove shock bolt and rein­stall with bolt head facing out­board for sway bar clearance.

TORQUE TABLE

Bolt Size 3/8”— 25 ft lbs * Bolt Size 7/16”— 35 ft lbs* Bolt Size 1/2”—60 ft lbs *

SAFETY: BEFORE BEGINNING INSTALLATION BE SURE TO SET THE PARKING BRAKE

AND CHOCK THE WHEELS.

NOTE: TO EASE INSTALLATION AND PROPERLYADJUST 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 UNIT IS DESIGNED TO MOUNT TO THE BOTTOM OF THE AXLE TUBES WITH

THE ARMS OF THE BAR TOWARD THE REAR OF THE VEHICLE.

1. Place the D shaped bushings onto the straight areas of the bar on each side of the center hump.

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. The

threads of the U-Bolts will point down.

3. Remove brake cable/line bracket from axle and use single flat plate to relocate higher.

4. Place 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 nuts provided. LEAVE

LOOSE AT THIS TIME to allow for adjustment later. For additional bar clearance remove the driver side
lower shock bolt, turn it around and reinstall from the opposite side of the lower shock bracket.

7892 (R-7892) 12/29/08

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

Driver’s Side

Passenger Side

9/16” nut

9/16” nut

5. Locate existing spare tire crossmember on vehicle frame. Place square U-bolt over the frame rail in front of the crossmem­ber with legs of the U-bolt pointing downward.

6. Insert the legs of the U-bolt into slotted holes of the frame brackets. Using 1/2” locknuts and washers, install the frame
bracket with the centered clevis on the driver side of vehicle as shown in photos. Install the frame bracket with the offset
clevis on passenger side of vehicle as shown in photos. LEAVE LOOSE for adjustment later. ( FINAL TIGHTENING

ON FRAME U-BOLTS : Push outer u-bolt leg against frame rail. Snug nuts to frame bracket then torque out­board nut first to 20 ft-lb and then inboard nut to 20 ft-lb. Final torque outboard nut first to 35 ft-lb and then in­board nut to 35 ft-lb. )

7. Attach clevis to end of sway bar with 1/2 x1-1/2” bolt, thick washer and locknut. 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.

9. .Insert hourglass bushing first and then sleeve into the loops of the end link assembly. Lubricatethe bushing and sleeve

to ease assembly.

10. Attach end links to clevis on frame bracket and sway bar as shown using the 7/16 x 2 1/4” bolts. Torque to 35 ft-lb.

11. Align bar from side to side through the D-bushings to be as centered as possible. Rotate bar front to rear by rotating the U­Bolts on the axle. Adjust frame brackets so that the end-links are straight up and down as possible. Be sure the bar does

not contact the differential, shocks, or leaf springs.

12. Torque axle U-bolts to 50-60 ft-lb. Tighten 9/16” nut on end links to lock adjustment.

13. Torque all of the mounting hardware to the specified rates. Bounce vehicle, checking for clearance on all undercarriage
components, ie: exhaust, shocks, fuel lines, brake lines, etc. Recheck installation periodically on a regular basis.

ATTENTION INSTALLER: PLEASE MAKE SURE CUSTOMER RECEIVES THIS INSTRUCTION

SHEET,ALL IMPORTANT NOTE CARDS, WARNING CARDS AND THE
WARRANTY FORM

7892 (R-7892) 12/29/08